Extremely cold environment freezing-resistant control cable with flexible filling core

Abstract

The invention relates to the technical field of cables, discloses an extremely cold environment freezing-resistant control cable with a flexible filling core, and aims to solve the problems that an existing cable is easy to loosen in structure and lower in electrical performance under extremely cold. The cable takes the flexible filling core as a core, and a flexible conduction pipe with a communication hole penetrates through a central through hole of the flexible filling core; anti-freezing filling liquid is poured into the pipe; a conductor wire core with a conductor insulation layer is spirally wound around the flexible filling core, a foaming filling layer, a leakage-proof sealing layer and an insulation protection layer are sequentially arranged on the outer side of the flexible filling core, the flexible conduction pipe can be further connected with an external heating circulation module, the liquid temperature is accurately controlled, hardening and embrittlement of materials under extremely cold conditions can be prevented, the internal structure is kept compact, and cold resistance and reliability are improved.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a freeze-resistant control cable for extremely cold environments with a flexible filled core. Background Technology

[0002] Existing control cables often face numerous technical challenges in extremely cold environments. When the ambient temperature is extremely low, the materials inside the cable are prone to hardening, embrittlement, and even shrinkage, leading to a loose cable structure, decreased electrical performance, and shortened service life. For example, the insulation material inside the cable may lose its elasticity at low temperatures, resulting in poor bending resistance and easy cracking. In addition, due to material shrinkage in extremely cold environments, voids may form inside the cable, reducing the stability of cable operation and increasing the risk of damage.

[0003] Some existing cold-resistant cables mainly address the low-temperature problem by selecting low-temperature resistant materials or adding an external protective layer. However, this often increases the cost and complexity of the cable and has limited effect on improving the stability and protection of the internal structure of the cable at extreme low temperatures. Especially in extremely cold environments such as -60°C or even lower, simple cold-resistant materials or external protection cannot completely solve the problem of loose structure and unstable electrical performance caused by material shrinkage and stress concentration inside the cable. Moreover, when the cable works in an extremely cold environment for a long time, if its internal structure cannot maintain a continuous antifreeze or constant temperature state, its reliability and safety will be greatly reduced. Summary of the Invention

[0004] The technical problem to be solved by this invention is that existing cables are prone to structural loosening and electrical performance degradation in extremely cold environments. To address this, we propose a freeze-resistant control cable for extremely cold environments with a flexible filled core.

[0005] To achieve the above objectives, this application adopts the following technical solution: a flexible-filled core freeze-resistant control cable for extremely cold environments, comprising: a flexible-filled core, wherein at least one conductor core is spirally wound around the flexible-filled core, each conductor core is wrapped with a conductor insulation layer, the conductor core and conductor insulation layer are wrapped with a leak-proof sealing layer, a foamed filling layer is filled between the flexible-filled core, conductor insulation layer and leak-proof sealing layer, an insulating protective layer is wrapped around the leak-proof sealing layer, a through hole is opened in the center of the flexible-filled core, a flexible conductive tube passes through the through hole, the flexible conductive tube is densely provided with connecting holes, plugs are provided at both ends of the flexible conductive tube, and antifreeze filling liquid is filled inside the flexible conductive tube, the antifreeze filling liquid is immersed into the flexible-filled core through the connecting holes.

[0006] Furthermore, the flexible filling core is made of flexible sponge material, and the density of the flexible sponge is 20-50 kg / m³.

[0007] Furthermore, the conductor core is wrapped around the outside of the flexible filler core with a preload of 5-15N, and the depth of the conductor core semi-embedded in the flexible filler core is 1 / 2-2 / 3 of the conductor core diameter, and the spacing between two adjacent conductor cores is greater than 2mm.

[0008] Furthermore, the antifreeze filler fluid is selected from at least one of dimethyl silicone oil, polyisobutylene, and modified silicone oil, and the freezing point of the antifreeze filler fluid is below -60°C, and the insulation resistance is greater than 10 Ω·cm. 12 Ω・cm.

[0009] Furthermore, the diameter of the connecting hole of the flexible conductive tube is 0.5-2mm, and 3-5 connecting holes are opened per centimeter along the length of the flexible conductive tube.

[0010] Furthermore, the leak-proof sealing layer is a modified butyl rubber layer or a fluororubber layer, and the thickness of the leak-proof sealing layer is 1-3mm, the temperature resistance range is -50℃ to 80℃, and the leakage rate is less than 0.01mL / 24h.

[0011] Furthermore, the foamed filler layer is a polyurethane foam layer or a polyethylene foam layer, and the foaming ratio of the foamed filler layer is 10-20 times, with a thermal conductivity of less than 0.03 W / (m·K).

[0012] Furthermore, the conductor insulation layer is a cross-linked polyethylene layer or a polytetrafluoroethylene layer, and the thickness of the conductor insulation layer is 0.8-2mm, the temperature resistance range is -60℃ to 100℃, and the breakdown voltage is greater than 20kV / mm.

[0013] Furthermore, the cross-sectional shape of the flexible filler core is quadrilateral, pentagonal, or hexagonal, and the number of conductor cores is consistent with the number of sides of the cross-section of the flexible filler core, and the conductor cores are uniformly distributed along the circumference of the cross-section of the flexible filler core.

[0014] Furthermore, the plugs at both ends of the flexible conductive tube are detachable, and the flexible conductive tube can be connected to an external heating and circulation module through the interfaces at the plugs at both ends. The external heating and circulation module can circulate the antifreeze filling fluid in the flexible conductive tube at a flow rate of 0.5-2L / min, and the temperature of the antifreeze filling fluid is controlled at 5-20℃ during the circulation process.

[0015] The technical effects and advantages of this invention are as follows: 1. By setting a flexible conductive tube filled with antifreeze filling fluid in the center of the flexible filler core, and allowing the antifreeze filling fluid to penetrate into the flexible filler core through the connecting hole, continuous antifreeze and heat preservation of the core area inside the cable is achieved. This effectively reduces the material hardening and embrittlement caused by low temperatures in extremely cold environments, and enhances the overall cold resistance of the cable. 2. As a core support, the flexible filler core is tightly bonded to and semi-embedded with the conductor core under pre-tightening force. When the ambient temperature decreases and the conductor core contracts, the flexible filler core is squeezed and releases the antifreeze filling fluid it has absorbed, filling the gaps created by the conductor core contraction, maintaining the tightness of the internal structure of the cable, actively resisting the structural loosening caused by low temperatures, and improving the mechanical stability and reliability of the cable. 3. The detachable plugs and interface design at both ends of the flexible conductive tube allow the cable to be connected to external heating and circulation modules. In extreme low temperatures or when long-term operation is required, the antifreeze filling fluid can be heated and circulated, providing active temperature control to ensure that the inside of the cable is always at a suitable temperature, greatly expanding the cable's application range and environmental adaptability. 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 external structure of the present invention; Figure 2 This is a cross-sectional structural diagram of the present invention; Figure 3 This is a schematic diagram of the cross-sectional structure of the flexible filling core of the present invention.

[0018] Legend: 1. Flexible filler core; 2. Conductor core; 3. Conductor insulation layer; 4. Foamed filler layer; 5. Leak-proof sealing layer; 6. Insulating protective layer; 7. Flexible conductive tube; 701. Connecting hole. Detailed Implementation

[0019] The technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. The components of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of this application, but merely represents selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application. It should be noted that similar reference numerals and letters in the following drawings indicate similar items; therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings. Furthermore, in the description of this application, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0020] Example 1: Refer to Figure 1 - Figure 3 The present invention provides a freeze-resistant control cable for extremely cold environments with a flexible filler core, which includes a flexible filler core 1, a conductor core 2, a conductor insulation layer 3, a foamed filler layer 4, a leak-proof sealing layer 5, an insulation protection layer 6, and a flexible conductive tube 7.

[0021] Specifically, the flexible filler core 1 of the present invention is located at the center of the cable. The material of the flexible filler core 1 is flexible sponge, and its density range is preferably 20-50 kg / m³. For example, polyurethane sponge or silicone rubber sponge can be used to ensure good elasticity and flexibility in extremely cold environments and to fully absorb and contain antifreeze filling liquid. The cross-section of the flexible filler core 1 is quadrilateral to accommodate the arrangement of four conductor cores 2.

[0022] At least one conductor core 2 is spirally wound around the flexible filler core 1. In this embodiment, four conductor cores 2 are provided, which are evenly distributed along the circumferential direction of the cross-section of the flexible filler core 1. Each conductor core 2 is wrapped with a conductor insulation layer 3. The conductor insulation layer 3 is a cross-linked polyethylene layer with a thickness of 1.5 mm, a temperature resistance range of -60℃ to 100℃, and a breakdown voltage greater than 20 kV / mm, ensuring excellent insulation performance under extremely cold conditions. The conductor cores 2 are wrapped and embedded in the flexible filler core 1 with a preload of 10 N. The conductor core 2 is partially embedded in the flexible filler core 1 to a depth of 1 / 2 to 2 / 3 of the diameter of the conductor core 2. In this embodiment, the conductor core 2 is half the diameter of the flexible filler core 1, which allows the conductor core 2 to be tightly bonded to the flexible filler core 1 and to effectively compress the flexible filler core 1 when the conductor core 2 shrinks at low temperature. The spacing between two adjacent conductor cores 2 is greater than 2 mm, for example, it can be designed to be 3 mm, to ensure sufficient electrical insulation distance and structural stability, and to prevent short circuits or contact during low temperature shrinkage.

[0023] Outside the conductor core 2 and conductor insulation layer 3, a leak-proof sealing layer 5 is wrapped. The leak-proof sealing layer 5 is made of modified butyl rubber with a thickness of 2mm. This material has excellent low temperature resistance and sealing performance, with a temperature range of -50℃ to 80℃ and a leakage rate of less than 0.01mL / 24h, effectively preventing the antifreeze filling fluid from overflowing.

[0024] A foamed filling layer 4 is filled between the flexible filling core 1, the conductor insulation layer 3, and the leak-proof sealing layer 5. The foamed filling layer 4 is a polyurethane foam layer with a foaming ratio of 15 times and a thermal conductivity of less than 0.03 W / (m·K). It provides good thermal insulation effect, reduces heat loss, helps maintain internal temperature, and enhances antifreeze performance.

[0025] The leak-proof sealing layer 5 is wrapped with an insulating protective layer 6, which provides external mechanical protection and insulation for the cable.

[0026] A through hole is formed at the center of the flexible filling core 1, and a flexible conductive tube 7 passes through the through hole. For example... Figure 1 As shown, the flexible conductive tube 7 has densely arranged connecting holes 701, each with a diameter of 1 mm. Four connecting holes 701 are arranged every centimeter along the length of the flexible conductive tube 7 to ensure that the antifreeze filling fluid can be evenly and fully immersed into the flexible filling core 1. Removable plugs are provided at both ends of the flexible conductive tube 7. The flexible conductive tube 7 is filled with antifreeze filling fluid, which is made of dimethyl silicone oil. This antifreeze filling fluid has a freezing point below -60℃ and an insulation resistance greater than 10¹²Ω·cm, exhibiting excellent low-temperature resistance and insulation performance. The antifreeze filling fluid is immersed into the flexible filling core 1 through the connecting holes 701, fully saturating the flexible filling core 1 and thus providing continuous antifreeze protection along the entire length of the cable.

[0027] When the ambient temperature drops, conductor core 2 will shrink. Since conductor core 2 is spirally wound and semi-embedded in flexible filler core 1 under pre-tightening force, its shrinkage will further compress flexible filler core 1. After being compressed, the antifreeze filler fluid absorbed inside flexible filler core 1 will be released to fill the tiny gaps created by the shrinkage of conductor core 2, thereby maintaining the tightness of the internal structure of the cable and preventing structural loosening caused by low-temperature shrinkage. At the same time, the presence of antifreeze filler fluid also further enhances the overall heat insulation and antifreeze effect of the cable. In addition, the plugs at both ends of flexible conduit 7 can be connected to external heating and circulation modules. When needed, the external heating and circulation modules can circulate the antifreeze filler fluid in flexible conduit 7 at a flow rate of 1L / min, and the temperature of the antifreeze filler fluid is controlled at 10℃ during the circulation process. This active heating and circulation mechanism enables the cable to maintain a stable internal temperature through human intervention in extreme or continuous extremely cold environments, ensuring the reliable operation of the cable.

[0028] Example 2: In this example, the cross-section of the flexible filling core 1 is pentagonal, and five conductor cores 2 are spirally wound around it. They are evenly distributed along the circumference of the cross-section of the flexible filling core 1. The material of the flexible filling core 1 is still flexible sponge with a density of 30kg / m³.

[0029] The conductor insulation layer 3 is a polytetrafluoroethylene layer with a thickness of 1 mm, which has a wider temperature range and better insulation performance.

[0030] The leak-proof sealing layer 5 is a fluororubber layer with a thickness of 1.5mm. It has stronger temperature resistance and sealing performance, ensuring reliable operation even under more severe cold conditions.

[0031] The foamed filler layer 4 is a polyethylene foam layer with a foaming ratio of 12 times and a thermal conductivity of 0.025 W / (m·K), which further improves the heat preservation effect.

[0032] The antifreeze filler fluid is made of polyisobutylene, which has a freezing point far below -60℃ and excellent insulation resistance. The connecting hole 701 of the flexible conductive tube 7 has a diameter of 0.8mm, and three connecting holes 701 are opened every centimeter along the length of the flexible conductive tube 7.

[0033] The conductor core 2 is wrapped with a preload of 8N and the semi-embedded depth is 2 / 3 of the diameter of the conductor core 2.

[0034] When connected to an external heating and circulation module, the circulation flow rate is controlled at 0.8 L / min, and the temperature of the antifreeze filling fluid is controlled at 15℃.

[0035] This embodiment further improves the overall performance and reliability of the cable in extremely cold environments by optimizing material selection and parameters.

[0036] Example 3: In this example, the cross-section of the flexible filler core 1 is hexagonal, and six conductor cores 2 are spirally wound around it. They are evenly distributed along the circumference of the cross-section of the flexible filler core 1, and the density of the flexible filler core 1 is 40 kg / m³.

[0037] The conductor insulation layer 3 can be selected as a cross-linked polyethylene layer or a polytetrafluoroethylene layer, and its thickness can be selected between 0.8 and 2 mm, for example, 0.8 mm.

[0038] The antifreeze filler fluid is made of modified silicone oil, which has been specially formulated to maintain better fluidity and electrical insulation at extremely low temperatures.

[0039] The diameter of the connecting hole 701 of the flexible conductive tube 7 can be selected between 0.5 and 2 mm, for example 0.5 mm, and 3 to 5 connecting holes 701 can be opened per centimeter of length, for example 5. This dense connecting hole design can ensure that the antifreeze filling liquid can wet the flexible filling core 1 more quickly and evenly.

[0040] The thickness of the leak-proof sealing layer 5 can be selected between 1 and 3 mm, for example, 1 mm.

[0041] The foaming ratio of the foam filler layer 4 can be selected between 10 and 20 times, for example, 20 times. The preload of the conductor core 2 can be selected between 5 and 15 N, for example, 5 N.

[0042] When connected to an external heating and circulation module, the circulation flow rate is controlled between 0.5L / min and 2L / min, for example, 1.5L / min. During circulation, the temperature of the antifreeze filling fluid is controlled between 5°C and 20°C, for example, 5°C. This embodiment demonstrates the adjustability of multiple parameters, enabling the invention to be flexibly configured according to specific application environments and requirements to achieve optimal performance and cost-effectiveness.

[0043] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A freeze-resistant control cable for extremely cold environments with a flexible filled core, characterized in that, The device includes a flexible filler core, around which at least one conductor core is spirally wound. Each conductor core is wrapped with a conductor insulation layer. A leak-proof sealing layer is wrapped around the conductor core and the conductor insulation layer. A foam filler layer is filled between the flexible filler core, the conductor insulation layer, and the leak-proof sealing layer. An insulating protective layer is wrapped around the leak-proof sealing layer. A through hole is opened in the center of the flexible filler core, and a flexible conductive tube passes through the through hole. The flexible conductive tube has densely arranged connecting holes. Plugs are provided at both ends of the flexible conductive tube, and antifreeze filling fluid is filled inside the flexible conductive tube. The antifreeze filling fluid is immersed into the flexible filler core through the connecting holes.

2. The extremely cold environment freeze-resistant control cable with flexible filled core according to claim 1, characterized in that, The flexible filling core is made of flexible sponge material, and the density of the flexible sponge is 20-50 kg / m³.

3. The extremely cold environment freeze-resistant control cable with flexible filled core according to claim 1, characterized in that, The conductor core is wrapped around the outside of the flexible filler core with a preload of 5-15N, and the conductor core is partially embedded in the flexible filler core to a depth of 1 / 2-2 / 3 of the conductor core diameter. The spacing between two adjacent conductor cores is greater than 2mm.

4. The extremely cold environment freeze-resistant control cable with flexible filled core according to claim 1, characterized in that, The antifreeze filler fluid is selected from at least one of dimethyl silicone oil, polyisobutylene, and modified silicone oil, and the freezing point of the antifreeze filler fluid is below -60℃, and the insulation resistance is greater than 10 Ω·cm. 12 Ω・cm.

5. The extremely cold environment freeze-resistant control cable with flexible filled core according to claim 1, characterized in that, The diameter of the connecting hole of the flexible conductive tube is 0.5-2mm, and 3-5 connecting holes are opened per centimeter along the length of the flexible conductive tube.

6. The extremely cold environment freeze-resistant control cable with flexible filled core according to claim 1, characterized in that, The leak-proof sealing layer is either a modified butyl rubber layer or a fluororubber layer, and the thickness of the leak-proof sealing layer is 1-3mm, the temperature resistance range is -50℃ to 80℃, and the leakage rate is less than 0.01mL / 24h.

7. The extremely cold environment freeze-resistant control cable with flexible filled core according to claim 1, characterized in that, The foamed filler layer is a polyurethane foam layer or a polyethylene foam layer, and the foaming ratio of the foamed filler layer is 10-20 times, with a thermal conductivity of less than 0.03 W / (m·K).

8. The extremely cold environment freeze-resistant control cable with flexible filled core according to claim 1, characterized in that, The conductor insulation layer is a cross-linked polyethylene layer or a polytetrafluoroethylene layer, and the thickness of the conductor insulation layer is 0.8-2mm, the temperature resistance range is -60℃ to 100℃, and the breakdown voltage is greater than 20kV / mm.

9. The extremely cold environment freeze-resistant control cable with flexible filled core according to claim 1, characterized in that, The flexible filler core has a cross-sectional shape of quadrilateral, pentagon, or hexagon, and the number of conductor cores is consistent with the number of sides of the flexible filler core's cross-section. The conductor cores are evenly distributed along the circumference of the flexible filler core's cross-section.

10. The extremely cold environment freeze-resistant control cable with flexible filled core according to claim 1, characterized in that, The plugs at both ends of the flexible conduit are detachable, and the flexible conduit can be connected to an external heating and circulation module through the interfaces at the plugs at both ends. The external heating and circulation module can circulate the antifreeze filling fluid in the flexible conduit at a flow rate of 0.5-2L / min, and the temperature of the antifreeze filling fluid is controlled at 5-20℃ during the circulation process.

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