A bend-resistant cable

Abstract

The application relates to the cable technical field and discloses a bending-resistant cable, which is sequentially provided with an inner cable, a buffer layer, a separation structure, an insulation layer, a sheath layer and an outer sheath from inside to outside; the buffer layer is a non-Newtonian fluid with insulating properties; the buffer layer wraps the inner cable; the separation structure comprises a plurality of separation sheets which are arranged at equal intervals; the outer side of the sheath layer is provided with a zigzag line along the axial direction of the cable; and the outer sheath is arranged at the bending position of the cable; when the cable is used, the filling foam, the buffer layer, the separation structure and the outer sheath form a cooperative buffer system; the filling foam provides rigid buffer support; the buffer layer provides fluid flow buffer; the separation structure provides elastic adaptive buffer; and the outer sheath provides structure constraint protection; the multiple buffer mechanisms jointly act to effectively disperse the stress generated by excessive bending, prevent the cable from further deforming excessively, avoid the damage of core structures such as the inner cable and the insulation layer, and significantly enhance the bending limit and service life of the cable.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cables, in particular to a bend-resistant cable. BACKGROUND

[0002] As the core carrier of power transmission and signal communication, cables are facing increasingly complex dynamic working condition challenges. In actual application, from large new energy vehicle charging piles to small charging cables of electronic products, all of them need to be frequently plugged and bent. However, long-term frequent plugging and bending of charging cables often leads to damage at the bending part of the charging cable, thereby affecting the performance of the cable.

[0003] The reasons why the existing cable is prone to damage after long-term bending are as follows: 1. The adhesion between the conductor and the insulating layer is insufficient, and gaps are easily generated in the long-term dynamic bending process, which leads to relative displacement of the two, causes micro-cracks or peeling of the insulating layer, and further affects the electrical insulation performance; 2. The bending part of the cable lacks an effective buffering mechanism, and cannot fully disperse the local stress when bending, resulting in problems such as sheath wear, insulating layer cracking and internal conductor breakage. SUMMARY

[0004] In order to solve the technical problems of sheath wear, insulating layer cracking and internal conductor breakage caused by repeated bending of the cable in the prior art, the present application provides a bend-resistant cable.

[0005] The technical scheme provided by the embodiments of the present application is as follows:

[0006] The bend-resistant cable provided by the embodiments of the present application comprises, from inside to outside, an inner cable, a buffer layer, a separation structure, an insulating layer, a sheath layer and an outer sheath.

[0007] The buffer layer is a non-Newtonian fluid with insulating properties, and the buffer layer wraps the inner cable.

[0008] The separation structure comprises a plurality of equally spaced separation pieces, the separation piece comprises a hard inner ring on the inside and a soft outer ring on the outside, and an elastic connecting piece is arranged between the soft outer ring and the hard inner ring, the hard inner ring is sleeved on the outside of the inner cable, and the soft outer ring is fixedly connected with the insulating layer and used for separating the buffer layer into multiple sections.

[0009] The outer side of the sheath layer is provided with a fold line along the axial direction of the cable.

[0010] The outer sheath is arranged at the bending part of the cable, the outer sheath is sleeved on the outside of the sheath layer and matches the fold line, a radial separation layer is arranged in the outer sheath to separate the outer sheath into an inner chamber and an outer chamber, and the filler in the inner chamber can react with the filler in the outer chamber to generate a filling foam.

[0011] As a further scheme of the present application, the inner cable comprises a conductor wire wrapped by an arbitrary outer skin.

[0012] As a further embodiment of the present invention, the buffer layer is a modified shear-thickening gel with added insulating material.

[0013] As a further aspect of the present invention, an elastic connecting mesh is provided between the soft outer rings of the multiple separators, and the shape of the hard inner ring of the separator corresponds to the shape of the inner cable, which is used to constrain the position of the inner cable.

[0014] As a further embodiment of the present invention, a constraint ring is provided at one end of the outer sheath, and a connecting Velcro is provided at the other end of the outer sheath. After the outer sheath wraps around the sheath layer once, its other end passes through the constraint ring and wraps around in the opposite direction.

[0015] As a further embodiment of the present invention, the radial separation layer is formed by bonding multiple separation strips side by side, with the separation strips arranged along the axial direction of the outer sheath.

[0016] As a further aspect of the present invention, the filling materials of the inner chamber and the outer chamber are carbon dioxide and sodium alkoxide, respectively.

[0017] The beneficial effects of the technical solutions provided in the embodiments of the present invention include at least the following:

[0018] In this embodiment of the invention, the filling foam, buffer layer, separation structure, and outer sheath form a synergistic buffering system. The filling foam provides rigid buffer support, the buffer layer provides fluid flow buffer, the separation structure provides elastic adaptation buffer, and the outer sheath provides structural constraint protection. The combined effect of multiple buffering mechanisms effectively disperses the stress generated by excessive bending, prevents the cable from undergoing further excessive deformation, avoids damage to the core structure such as the inner cable and insulation layer, and significantly enhances the bending limit and service life of the cable. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the overall structure of a bend-resistant cable proposed in this invention.

[0021] Figure 2 This is a schematic diagram of the sheath layer of a bend-resistant cable proposed in this invention.

[0022] Figure 3 This is a schematic diagram of the separation structure of a bend-resistant cable proposed in this invention.

[0023] Figure 4This is a schematic diagram of the partition structure of a bend-resistant cable proposed in this invention.

[0024] Figure 5 This is a schematic diagram of a separator for a bend-resistant cable proposed in this invention.

[0025] Figure 6 This is a schematic diagram of the outer sheath of a bend-resistant cable proposed in this invention.

[0026] Figure 7 This is a schematic diagram of the radial separator layer of a bend-resistant cable proposed in this invention.

[0027] Reference numerals: 100, inner cable; 200, buffer layer; 300, partition structure; 301, partition plate; 310, rigid inner ring; 320, flexible outer ring; 330, elastic connecting piece; 340, elastic connecting mesh; 400, insulation layer; 500, sheath layer; 510, zigzag pattern; 600, outer sheath; 610, radial partition layer; 620, inner chamber; 630, outer chamber; 640, restraint ring; 650, connecting Velcro.

[0028] As shown in the figure, specific structures and devices are marked in the figure to clearly illustrate the structure of the embodiments of the present invention. However, this is only for illustrative purposes and is not intended to limit the present invention to this specific structure, device and environment. Those skilled in the art can adjust or modify these devices and environments according to specific needs. Detailed Implementation

[0029] The technical solutions of the present invention will now be described with reference to the accompanying drawings. It should be noted that, to make the embodiments more detailed, the following embodiments are the best and preferred embodiments, and those skilled in the art can use other alternative methods to implement some well-known technologies. Furthermore, the accompanying drawings are only for more specific description of the embodiments and are not intended to specifically limit the present invention.

[0030] like Figures 1 to 7 As shown, an embodiment of the present invention provides a bend-resistant cable, comprising: an inner cable 100, a buffer layer 200, a separator structure 300, an insulation layer 400, a sheath layer 500, and an outer sheath 600 arranged sequentially from the inside to the outside.

[0031] like Figure 1 As shown, the inner cable 100 includes any number of conductor wires wrapped with an outer sheath.

[0032] like Figure 3As shown, the buffer layer 200 is a non-Newtonian fluid with insulating properties. The buffer layer 200 is a modified shear-thickening gel with added insulating material. The buffer layer 200 is tightly attached to the surface of the inner cable 100 through a special wrapping process, which not only achieves preliminary buffer protection for the inner cable 100, but also avoids electrical interference between the inner cable 100 and the external structure by means of its insulating properties.

[0033] like Figure 4 and Figure 5 As shown, the partition structure 300 includes a plurality of partition pieces 301 arranged at equal intervals. Each partition piece 301 includes an inner rigid inner ring 310 and an outer flexible outer ring 320. An elastic connecting piece 330 is provided between the flexible outer ring 320 and the rigid inner ring 310. The rigid inner ring 310 is sleeved on the outside of the inner cable 100. The flexible outer ring 320 is fixedly connected to the insulation layer 400 to divide the buffer layer 200 into multiple segments. An elastic connecting mesh 340 is provided between the flexible outer rings 320 of the plurality of partition pieces 301. The shape of the rigid inner ring 310 of the partition piece 301 corresponds to the shape of the inner cable 100 to constrain the position of the inner cable 100.

[0034] In this invention, the rigid inner ring 310 of the separator 301 precisely matches the shape of the inner cable 100, effectively constraining the radial position of the inner cable 100 and preventing its displacement during use. Simultaneously, the soft outer ring 320 of the separator 301 is fixedly connected to the subsequently installed insulation layer 400. Through the combined structure of the rigid inner ring 310, the elastic connecting piece 330, and the soft outer ring 320, the continuous buffer layer 200 is divided into multiple relatively independent buffer segments, solving the problem of insufficient adhesion and loose connection between the inner cable 100 and the insulation layer 400 due to the presence of the buffer layer 200. Based on this, an elastic connecting mesh 340 is added between the soft outer rings 320 of multiple separators 301 to further strengthen the overall strength of the separator structure 300, while giving the cable a certain degree of resilience to prepare for subsequent bending stress. Due to the presence of the soft outer rings 320 and the elastic connecting mesh 330, as well as the setting of the buffer layer 200, the influence of the insulation layer 400 on the inner cable 100 can be greatly reduced. That is, when the insulation layer 400 is slightly deformed, it will not affect the state of the inner cable 100, so that the inner cable 100 can be in a relatively stable state during daily use.

[0035] It is worth noting that the present invention, through the design of separating the inner cable 100 and the insulation layer 400 by the separation structure 300 and the buffer layer 200, can also allow the buffer layer 200 to flow within each buffer section. When the cable body bends, the outer side of the bending section expands and the inner side contracts, causing the buffer layer 200 to move from the inner side to the outer side. The movement of the buffer layer 200, in turn, squeezes the inner cable 100. That is, when the cable body bends, the bending amplitude of the outer insulation layer 400 is greater than that of the inner cable 100, thereby making the change of the inner cable 100 relatively small relative to the change of the cable body, enhancing the stability of the inner cable 100 and reducing the risk of the inner cable 100 breaking due to bending.

[0036] like Figure 2 and Figure 3 As shown, the outer side of the sheath layer 500 is provided with zigzag lines 510 along the cable axis. In this invention, the sheath layer 500 is produced by injection molding on the outside of the insulation layer 400. After injection molding, an additional pressing process is added to press zigzag lines 510 on the outer side of the sheath layer 500 along the cable axis. The zigzag lines 510 not only provide a positioning base for the subsequent installation of the outer sheath 600 and prevent the outer sheath 600 from slipping out of the designated position, but also play a role in limiting excessive bending during cable use (when the bending range of the cable of this invention is too large, the raised part of the zigzag lines 510 can act as an obstacle to limit further bending of the cable). At the same time, there is no need to make major modifications to the existing injection molding production line, the production process is easy to adjust, and the structural function and production economy are taken into account.

[0037] like Figure 1 and Figure 6 As shown, the outer sheath 600 is positioned at the cable bend. The outer sheath 600 is fitted over the outer side of the sheath layer 500 and matches the zigzag pattern 510. This coordinated design effectively prevents the outer sheath 600 from slipping off at the designated position during use, ensuring the stability of the protection. Figure 7 As shown, a radial partition layer 610 is provided inside the outer sheath 600 to divide the outer sheath 600 into an inner chamber 620 and an outer chamber 630. The filling material in the inner chamber 620 can react with the filling material in the outer chamber 630 to generate filling foam.

[0038] In this invention, the outer sheath 600 is a separate structure from the main cable body. It needs to be separately fitted onto the bend of the main cable body according to the actual usage, in order to reduce the complexity of the cable production process and the production cost of this invention.

[0039] like Figure 1 and Figure 6As shown, one end of the outer sheath 600 is provided with a constraint ring 640, and the other end of the outer sheath 600 is provided with a connecting Velcro 650. After the outer sheath 600 wraps around the sheath layer 500 once, its other end passes through the constraint ring 640 and wraps around in the opposite direction. That is, the outer sheath 600 of the present invention can adjust its own diameter according to the diameter of the inner cable body, so that the outer sheath 600 is suitable for cable bodies of different sizes, and the tightness of the outer sheath 600 constraining the cable body can be manually adjusted to ensure the protective effect and ease of use.

[0040] like Figure 7 As shown, the radial separation layer 610 is formed by bonding multiple separation strips side by side. The separation strips are arranged along the axial direction of the sheath layer 500. The filling materials in the inner cavity 620 and the outer cavity 630 are carbon dioxide and sodium alkoxide, respectively.

[0041] When the cable body is bent excessively, the axially arranged separators are pulled apart due to the external stretching of the cable body during bending. This causes the carbon dioxide and sodium alkoxide filling the inner chamber 620 and outer chamber 630 to mix and generate filling foam, thereby further forming a buffer, dispersing the local stress generated when the cable is bent, and enhancing the bending resistance of the cable.

[0042] The partition structure 300 in the overall device, through the cooperation of its rigid inner ring 310 and soft outer ring 320, can work with the internal non-Newtonian fluid buffer layer 200 to achieve stress absorption and redistribution during dynamic bending, and can also work with the external sheath layer 500 and radial partition layer 610 to trigger a chemical foaming reaction during extreme bending, thus forming a full-range, multi-level protection system from daily to extreme working conditions.

[0043] The workflow and working principle of this invention:

[0044] First, when the cable is bent by external force in daily scenarios, the bent section exhibits deformation characteristics of expansion on the outside and contraction on the inside. At this time, the buffer layer 200 (non-Newtonian fluid), which is divided into multiple independent buffer sections by the separation structure 300, flows from the inside of the bend to the outside under the action of deformation pressure. The flowing buffer layer 200 generates a uniform squeezing force on the inner cable 100 on the inside. This force can offset part of the deformation stress caused by the bend. At the same time, due to the non-Newtonian fluid characteristics of the buffer layer 200, it can absorb some of the bending energy during its flow, reducing the stress directly transmitted to the inner cable 100.

[0045] The elastic connecting piece 330 and the elastic connecting mesh 340 in the separation structure 300 work synchronously. The elastic connecting piece 330 undergoes elastic deformation as the cable bends, preventing the separation structure 300 itself from hindering the cable bending. At the same time, it buffers some stress through deformation. The elastic connecting mesh 340 uses its resilience to offset the pressure on the insulation layer 400 when bending, and can adapt to the deformation characteristics of the outer side extending and the inner side squeezing at the bend, ensuring that the separation structure 300 as a whole does not affect the normal bending of the cable.

[0046] Due to the flow buffer of the buffer layer 200 and the elastic adaptation of the separation structure 300, the deformation amplitude of the insulation layer 400 during bending is effectively absorbed, so that the bending amplitude of the inner cable 100 is much smaller than that of the cable body (especially the insulation layer 400). The inner cable 100 is always in a relatively stable state, avoiding the accumulation of deformation caused by frequent bending, significantly reducing the risk of breakage of the inner cable 100, and ensuring the continuity of the cable transmission function.

[0047] When the cable is subjected to a large external force and the bending radius approaches or reaches the limit value, the radial separation layer 610 inside the outer sheath 600 begins to function. The radial separation layer 610 is composed of multiple separators arranged side by side along the axial direction of the outer sheath 600 and bonded together. During excessive bending, the outside of the cable bend is stretched, which causes the axially arranged separators to be gradually pulled apart. After the separators are pulled apart, the inner chamber 620 divided by the radial separation layer 610 inside the outer sheath 600 is interconnected with the outer chamber 630. The carbon dioxide filled in the inner chamber 620 and the sodium alkoxide filled in the outer chamber 630 come into full contact after being connected and undergo a chemical reaction to generate filling foam. The filling foam expands rapidly in the chamber inside the outer sheath 600, filling the gap at the bend. The expanded filling foam can further disperse the local stress generated when the cable is bent, avoiding stress concentration at a certain point at the bend, thereby mitigating the impact of excessive bending on the internal structure of the cable (especially the inner cable 100).

[0048] Thus, the filling foam, buffer layer 200, separation structure 300, and outer sheath 600 form a synergistic buffering system. The filling foam provides rigid buffering support, the buffer layer 200 provides fluid flow buffering, the separation structure 300 provides elastic adaptation buffering, and the outer sheath 600 provides structural constraint protection. The combined effect of multiple buffering mechanisms effectively disperses the stress generated by excessive bending, prevents the cable from undergoing further excessive deformation, avoids damage to core structures such as the inner cable 100 and insulation layer 400, and significantly enhances the cable's bending limit and service life.

[0049] This invention encompasses any substitutions, modifications, equivalent methods, and solutions made within the spirit and scope of this invention. To provide the public with a thorough understanding of this invention, specific details are described in detail in the preferred embodiments, while those skilled in the art will fully understand the invention even without these details. Furthermore, to avoid unnecessary misunderstanding of the essence of this invention, well-known methods, processes, procedures, components, and circuits are not described in detail.

[0050] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A bend-resistant cable, characterized in that, include: The inner cable (100), buffer layer (200), separation structure (300), insulation layer (400), sheath layer (500) and outer sheath (600) are arranged sequentially from the inside to the outside. The buffer layer (200) is an insulating non-Newtonian fluid, the buffer layer (200) wraps the inner cable (100), and the buffer layer (200) is a modified shear-thickening gel with added insulating material; The separation structure (300) includes a plurality of equally spaced separation pieces (301). Each separation piece (301) includes an inner rigid inner ring (310) and an outer soft outer ring (320). An elastic connecting piece (330) is provided between the soft outer ring (320) and the rigid inner ring (310). The rigid inner ring (310) is sleeved on the outside of the inner cable (100). The soft outer ring (320) is fixedly connected to the insulation layer (400) to divide the buffer layer (200) into multiple segments. An elastic connecting net (340) is provided between the soft outer rings (320) of the plurality of separation pieces (301). The shape of the rigid inner ring (310) of the separation piece (301) corresponds to the shape of the inner cable (100) to constrain the position of the inner cable (100). The outer side of the sheath layer (500) is provided with zigzag lines (510) along the cable axis. The outer sheath (600) is disposed at the bend of the cable. The outer sheath (600) is sleeved on the outside of the sheath layer (500) and matches the zigzag pattern (510). The radial partition layer (610) disposed inside the outer sheath (600) divides the outer sheath (600) into an inner chamber (620) and an outer chamber (630). The filling material in the inner chamber (620) can react with the filling material in the outer chamber (630) to generate filling foam. The radial separation layer (610) is formed by bonding multiple separation strips side by side, and the separation strips are arranged along the axial direction of the outer sheath (600); The filling materials in the inner chamber (620) and the outer chamber (630) are carbon dioxide and sodium alkoxide, respectively.

2. The bend-resistant cable according to claim 1, characterized in that, The inner cable (100) includes any number of conductor wires wrapped with an outer sheath.

3. The bend-resistant cable according to claim 1, characterized in that, One end of the outer sheath (600) is provided with a constraint ring (640), and the other end of the outer sheath (600) is provided with a connecting Velcro (650). After the outer sheath (600) wraps around the sheath layer (500) once, its other end passes through the constraint ring (640) and wraps around in the opposite direction.

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