Ultraviolet resistant outdoor cold-resistant power cable adaptive to day-night temperature difference

Abstract

The present application relates to the technical field of cable, and discloses an ultraviolet-resistant outdoor cold-resistant power cable suitable for day-night temperature difference; the present application is provided with polyurea sealing microcapsule, hexagonal cell, microcapsule elastic sheet and stretch structure; in low-temperature environment, the polyurea sealing microcapsule shrinks, at this time, the microcapsule elastic sheet loses supporting force, starts to release elastic potential energy, the hexagonal cell deforms and starts to expand outward, the hexagonal cell expands outward and pushes the wave trough position of the stretch structure to expand outward, the stretch structure gradually expands from corrugated to cylindrical profile, under the expanding effect of the hexagonal cell and the stretch structure, the cable sheath layer is actively expanded to offset the shrinkage stress, effectively avoiding the problem of low-temperature embrittlement, meanwhile, the corrugated structure is designed to cope with the axial shrinkage of the cable sheath layer, the cable separation ring divides the cable into multiple independent units, decomposes the overall axial shrinkage into local small-amplitude shrinkage of each unit, avoiding the accumulation of shrinkage stress to cause the cable to twist and the cable insulation layer to crack.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a UV-resistant outdoor cold-resistant power cable that adapts to day and night temperature differences. Background Technology

[0002] Cables are flexible conductor assemblies composed of multiple layers of components, including conductive conductors, cable insulation layers, and protective structures. They are used in power systems or communication fields to safely transmit electrical energy and signals and are adaptable to different usage environments. Power cables are special cables used to transmit and distribute electrical energy. They consist of conductors, cable insulation layers, cable sheath layers, and auxiliary structures, and can be laid in various scenarios such as underground, overhead, and underwater.

[0003] Chinese Patent Publication No. CN214753054U discloses a cold-resistant power cable, relating to the field of cable technology. The cable includes an inner core and an outer layer, with a filler layer between the inner core and the outer layer. The inner core, from the inside out, comprises a conductive core, an inner cable insulation layer, and an inner cable sheath layer. The conductive core is composed of multiple strands of tin-plated copper conductors. The outer layer, from the inside out, comprises an inner armor layer, a cold-resistant layer, a waterproof layer, a flame-retardant layer, an outer cable insulation layer, a first armor layer, an outer cable sheath layer, and a second armor layer. Three inner cores are evenly distributed within the filler layer, and a reinforcing core is located at the center line of each inner core. This invention offers advantages such as better low-temperature resistance, flame retardancy, and improved cable flexibility.

[0004] The existing related technologies have the following defects: when used in low-temperature environments, existing power cables will become brittle. When subjected to external forces, the brittle cables may crack or even break, causing the cables to lose their protective capabilities. If the conductor breaks due to low-temperature brittleness, it will directly cause a power outage. Summary of the Invention

[0005] The technical problem to be solved by this invention is that existing power cables have the disadvantage of becoming brittle in low-temperature environments. To address this, we propose a UV-resistant, cold-resistant outdoor power cable that adapts to day-night temperature differences.

[0006] To achieve the above objectives, this application adopts the following technical solution: a UV-resistant outdoor cold-resistant power cable adaptable to day and night temperature differences, comprising: an aluminum alloy conductor, a cable insulation layer fixedly connected to the outer wall of the aluminum alloy conductor, an extruded inner liner fixedly connected to the outer wall of the cable insulation layer, a steel tape armored protective layer fixedly connected to the outer wall of the extruded inner liner, a hexagonal cell fixedly connected to the outer wall of the steel tape armored protective layer, microcapsule elastic sheets fixedly connected to the inner wall of the hexagonal cell, polyurea sealed microcapsules fixedly connected to the inner wall of the microcapsule elastic sheets, a connecting boss fixedly connected to the top of the hexagonal cell, a stretching structure fixedly connected to the top of the connecting boss, a cable sheath layer fixedly connected to the outer wall of the stretching structure, a UV ceramic coating applied to the outer wall of the cable sheath layer, a corrugated structure fixedly connected to the side of the cable sheath layer, and a cable separator ring fixedly connected to the other side of the corrugated structure.

[0007] Preferably, the extruded inner liner is made of modified low-density polyethylene, which is prepared by blending linear low-density polyethylene with an ethylene-propylene-diolefin terpolymer.

[0008] Preferably, the hexagonal cells are set at the same angle to the horizontal central axis of the aluminum alloy conductor of the cable, and there is a one-to-one correspondence between the hexagonal cells and the polyurea sealing microcapsules.

[0009] Preferably, the top and bottom of the microcapsule elastic sheet are fixedly connected to the hexagonal cell, and the microcapsule elastic sheet has an arc-shaped design.

[0010] Preferably, the polyurea sealing microcapsules are in an expanded state at room temperature and in a contracted state at low temperature.

[0011] Preferably, the connecting boss is designed in an I-shape, and the connecting boss plays a fixing role.

[0012] Preferably, the expansion structure is corrugated, with each trough of the expansion structure corresponding to a one-to-one hexagonal cell.

[0013] Preferably, each crest of the extended structure is fixedly connected to the cable sheath layer, and each trough of the extended structure is fixedly connected to the hexagonal cell.

[0014] Preferably, the cable separator rings are evenly spaced about the outer wall of the UV ceramic coating, and the corrugated structure is symmetrical about the vertical central axis of the cable separator rings.

[0015] Preferably, a first connecting block is fixedly connected at the connection between the hexagonal cell and the microcapsule elastic sheet, and a second connecting block is fixedly connected at the connection between the microcapsule elastic sheet and the polyurea sealed microcapsule.

[0016] The technical effects and advantages of this invention are as follows: This invention comprises polyurea sealing microcapsules, hexagonal cells, microcapsule elastic sheets, and a stretching structure. In low-temperature environments, the polyurea sealing microcapsules contract, causing the microcapsule elastic sheets to lose their supporting force and begin to release elastic potential energy. The hexagonal cells deform and begin to expand outward. As the hexagonal cells expand outward, they push the troughs of the stretching structure outward, gradually stretching the stretching structure from a corrugated shape to a cylindrical outline. Under the outward expansion of the hexagonal cells and the stretching structure, the cable sheath layer actively expands to offset the shrinkage stress, effectively avoiding the problem of low-temperature embrittlement. At the same time, the corrugated structure is designed to cope with the axial shrinkage of the cable sheath layer. The cable separator ring divides the cable into multiple independent units, decomposing the overall axial shrinkage into small-amplitude local shrinkage of each unit, avoiding the accumulation of shrinkage stress that could lead to cable twisting and cracking of the cable insulation layer. Attached Figure Description

[0017] 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:

[0018] Figure 1 This is a front view structural diagram of the cold-resistant power cable of the present invention; Figure 2 This is a schematic cross-sectional view of the cold-resistant power cable of the present invention. Figure 3 This is a schematic diagram of the structure of the aluminum alloy conductor portion of the cable according to the present invention; Figure 4 This is a schematic diagram of the structure of the extended structural part of the present invention; Figure 5 This is a schematic diagram of the hexagonal lattice cell portion of the present invention; Figure 6 This is a schematic diagram of the expansion structure of the hexagonal cell portion of the present invention; Figure 7 This is a structural schematic diagram of the connecting boss portion of the present invention; Figure 8 This is a schematic diagram of the cable sheath layer portion of the present invention.

[0019] Legend: 1. Cable aluminum alloy conductor; 2. Cable insulation layer; 3. Extruded inner lining layer; 4. Steel tape armored protective layer; 5. Hexagonal cell; 6. Microencapsulated elastic sheet; 7. Polyurea sealed microencapsulation; 8. Connecting boss; 9. Expansion structure; 10. Cable sheath layer; 11. UV ceramic coating; 12. Corrugated structure; 13. Cable separator ring; 14. Connecting block No. 1; 15. Connecting block No. 2. Detailed Implementation

[0020] 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.

[0021] According to the embodiments of the present invention, Figures 1 to 8 As shown.

[0022] Cables are composed of multiple layers of components, including conductive conductors, cable insulation layers 2, and protective structures. They are flexible conductor assemblies used in power systems or communication fields to safely transmit electrical energy and signals and adapt to different operating environments. Power cables are special cables used to transmit and distribute electrical energy, consisting of conductors, cable insulation layers 2, cable sheath layers 10, and auxiliary structures. They can be laid in various scenarios such as underground, overhead, and underwater. Outdoor power cables are widely used in cold regions, high-altitude areas, and outdoor scenarios with significant day-night temperature differences. Such environments place stringent requirements on the cable's cold resistance, structural stability, and long-term service reliability. In particular, the core protective and support structures, such as the cable sheath layer 10 and the extruded inner lining layer 3, need to maintain good toughness, impact resistance, and sealing and isolation capabilities under low temperature and extreme cold conditions to avoid performance degradation caused by environmental temperature fluctuations, thus ensuring the continuity and safety of power transmission.

[0023] In existing power cables, under severe cold environments or large diurnal temperature variations, the substrate of key structural components such as the cable sheath layer 10 and the extruded inner lining layer 3 will experience reduced molecular chain activity and decreased toughness due to low temperatures, leading to embrittlement. The impact resistance of the embrittled cable material decreases significantly. When subjected to bending forces, impact forces, constraint stress from environmental frost heave, or external mechanical forces, cracks are easily generated in the protective structures such as the cable sheath layer 10 and the extruded inner lining layer 3. Low temperatures accelerate crack propagation, ultimately destroying the integrity of the protective structure. This causes the cable to lose its physical protection and sealing isolation capabilities for the internal cable insulation layer 2 and conductor, leading to the intrusion of moisture and impurities, accelerating the aging of the internal cable insulation layer 2 and conductor corrosion. If the embrittlement spreads to the conductor, it can cause power transmission interruption, resulting in large-scale power outages, severely impacting the continuity of industrial production and the guarantee of electricity supply for residential use, and potentially causing safety hazards and significant economic losses. To solve this problem, this invention incorporates the following design in a UV-resistant outdoor cold-resistant power cable adapted to diurnal temperature variations:

[0024] An outdoor cold-resistant power cable adapted to diurnal temperature variations and UV protection includes: an aluminum alloy conductor 1, which is the core conductive component of the power cable, located at the radial center of the cable. Essentially, it is a conductive core made of a highly conductive metallic material. Its core function is to achieve efficient power transmission through the directional flow of current, serving as the core carrier for power transmission in the cable. An insulation layer 2 is fixedly connected to the outer wall of the aluminum alloy conductor 1. The insulation layer 2 is a key insulating component located on the outside of the conductor, radially and tightly covering it. Its core function is to achieve insulation between the conductor and the external structure. The cable insulation layer 2 provides electrical insulation to prevent current leakage and short circuit accidents. An extruded inner liner layer 3 is fixedly connected to the outer wall of the cable insulation layer 2. A steel strip armored protective layer 4 is fixedly connected to the outer wall of the extruded inner liner layer 3. The steel strip armored protective layer 4 is formed by winding and interlocking cold-rolled steel strips. Its core function is to provide mechanical protection against impact, pressure, and tension for the cable. Hexagonal cells 5 are fixedly connected to the outer wall of the steel strip armored protective layer 4. Microcapsule elastic sheets 6 are fixedly connected to the inner wall of the hexagonal cells 5. The microcapsule elastic sheets 6 are made of low-temperature resistant spring steel, a special type of spring steel optimized with added alloying elements such as nickel. Spring steel maintains high elasticity, toughness, and fatigue resistance in extremely cold environments, without brittleness or elasticity loss. It is suitable for core driving components in low-temperature scenarios, such as the microencapsulated elastic sheet 6 in cold-resistant cables. The inner wall of the microencapsulated elastic sheet 6 is fixedly connected to a polyurea-sealed microcapsule 7. The polyurea-sealed microcapsule 7 is a miniature sealed cavity structure with polyurea polymer material as the wall material and an internally encapsulated temperature-sensitive core material. As a temperature-sensitive support component for the microencapsulated elastic sheet 6 in the cold-resistant cable, it maintains an expanded state at room temperature by filling with the core material to support the microencapsulated elastic sheet 6. At low temperatures, the core material contracts, causing the entire capsule to contract. The top of the hexagonal cell 5 is fixedly connected to a connecting... A boss 8 is connected to the top of the boss 8. An extension structure 9 is fixedly connected to the top of the extension structure 8. A cable sheath layer 10 is fixedly connected to the outer wall of the extension structure 9. A UV ceramic coating 11 is coated on the outer wall of the cable sheath layer 10. The UV ceramic coating 11 is based on a ceramic base material and is compounded with UV stabilizers and cold-resistant toughening components. It is cured at low temperature to form a dense and uniform film structure. Its core function is to provide the cable with long-lasting anti-ultraviolet aging, low-temperature crack resistance, wear resistance and corrosion resistance integrated protection. A corrugated structure 12 is fixedly connected to the side of the cable sheath layer 10. A cable separator ring 13 is fixedly connected to the other side of the corrugated structure 12.

[0025] The extruded inner liner 3 is made of modified low-density polyethylene, which is prepared by blending linear low-density polyethylene with an ethylene-propylene-diolefin terpolymer. The hexagonal cells 5 are set at equal angles to the horizontal central axis of the cable aluminum alloy conductor 1. Each hexagonal cell 5 corresponds one-to-one with a polyurea sealing microcapsule 7. The top and bottom of the microcapsule elastic sheet 6 are fixedly connected to the hexagonal cells 5. The microcapsule elastic sheet 6 has an arc-shaped design. The polyurea sealing microcapsule 7 expands at room temperature and contracts at low temperature. The connecting boss 8 has an I-shaped design and serves to solidify... The expansion structure 9 is corrugated, with each trough of the expansion structure 9 corresponding to a hexagonal cell 5. Each peak of the expansion structure 9 is fixedly connected to the cable sheath layer 10, and each trough of the expansion structure 9 is fixedly connected to the hexagonal cell 5. The cable separator ring 13 is evenly spaced about the outer wall of the UV ceramic coating 11. The corrugated structure 12 is symmetrical about the vertical central axis of the cable separator ring 13. A first connecting block 14 is fixedly connected at the connection between the hexagonal cell 5 and the microcapsule elastic sheet 6, and a second connecting block 15 is fixedly connected at the connection between the microcapsule elastic sheet 6 and the polyurea sealing microcapsule 7.

[0026] During cable use, at room temperature, the polyurea-sealed microcapsules 7 expand, compressing the microcapsule elastic sheet 6 and maintaining it in a pre-compressed, energy-storing state. When the cable is in a low-temperature environment, the polyurea-sealed microcapsules 7 begin to contract, and with the disappearance of the supporting force on the microcapsule elastic sheet 6, the microcapsule elastic sheet 6 begins to release its elastic potential energy. Under the action of the microcapsule elastic sheet 6, the hexagonal cells 5 begin to deform, causing them to expand outwards. The hexagonal cells 5 are connected to the expansion structure 9 via connecting bosses 8. At this time, the troughs of the expansion structure 9 open... As the expansion begins, the originally corrugated, expansive structure 9 begins to transform into a cylindrical profile. The hexagonal cells 5 and the expansive structure 9 support the cable sheath layer 10, counteracting its radial shrinkage tendency at low temperatures. When the cable sheath layer 10 shrinks axially, the corrugated structure 12 adaptively adjusts according to the shrinkage situation to dissipate axial shrinkage stress. The cable separator ring 13 divides the cable on one hand to avoid the accumulation of overall shrinkage stress, and on the other hand, it plays a supporting role. Since the diameter of the cable separator ring 13 is larger than the diameter of the cable, the cable separator ring 13 can support the cable and reduce the risk of mechanical damage.

[0027] The cable sheath 10 is equipped with polyurea sealing microcapsules 7, hexagonal cells 5, microcapsule elastic sheets 6, and a stretching structure 9. In low-temperature environments, the polyurea sealing microcapsules 7 contract, causing the microcapsule elastic sheets 6 to lose support and release elastic potential energy. The hexagonal cells 5 deform and expand outwards, pushing the troughs of the stretching structure 9 outwards. The stretching structure 9 gradually expands from a corrugated shape to a cylindrical profile. Under the outward expansion action of the hexagonal cells 5 and the stretching structure 9, the cable sheath 10 actively expands to offset the contraction stress, effectively preventing low-temperature embrittlement. Simultaneously, the corrugated structure 12 is designed to cope with the axial contraction of the cable sheath 10. The cable separator ring 13 divides the cable into sections... Multiple independent units decompose the overall axial contraction into small local contractions of each unit, avoiding the accumulation of contraction stress that could lead to cable twisting and cracking of the cable insulation layer 2. Through active expansion at low temperatures, the low-temperature contraction stress of the cable sheath layer 10 is precisely offset, fundamentally solving the problems of cable sheath embrittlement and cracking and cable insulation layer 2 damage in cold environments. Combined with the adaptive adjustment of the corrugated structure 12 and the segmented design of the cable separator ring 13, the problems of cable twisting and conductor breakage caused by the accumulation of overall contraction stress are further avoided, reducing the risk of mechanical damage during outdoor laying and maintenance, extending the service life of cables in cold regions, and reducing the failure rate and subsequent maintenance costs.

[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 UV-resistant, cold-resistant outdoor power cable adapted to diurnal temperature variations, characterized in that, include: The cable has an aluminum alloy conductor, an outer wall fixedly connected to a cable insulation layer, an outer wall fixedly connected to an extruded inner liner, an outer wall fixedly connected to a steel tape armored protective layer, an outer wall fixedly connected to a hexagonal cell, an inner wall fixedly connected to a microcapsule elastic sheet, an inner wall fixedly connected to a polyurea sealing microcapsule (expanded at room temperature and contracted at zero degrees Celsius), a connecting boss fixedly connected to the top of the hexagonal cell, a corrugated structure fixedly connected to the top of the connecting boss, with each trough of the corrugated structure corresponding to a hexagonal cell, an outer wall fixedly connected to a cable sheath layer coated with a UV ceramic coating, a corrugated structure fixedly connected to the side of the cable sheath layer, and a cable separator ring fixedly connected to the other side of the corrugated structure.

2. The UV-resistant outdoor cold-resistant power cable adaptable to day and night temperature differences according to claim 1, characterized in that: The extruded inner liner is made of modified low-density polyethylene, which is prepared by blending linear low-density polyethylene with an ethylene-propylene-diolefin terpolymer.

3. The UV-resistant outdoor cold-resistant power cable adaptable to day and night temperature differences according to claim 1, characterized in that: The hexagonal cells are set at equal angles to the horizontal central axis of the aluminum alloy conductor of the cable, and there is a one-to-one correspondence between the hexagonal cells and the polyurea sealing microcapsules.

4. The UV-resistant outdoor cold-resistant power cable adaptable to day and night temperature differences according to claim 1, characterized in that: The top and bottom of the microcapsule elastic sheet are fixedly connected to the hexagonal cell, and the microcapsule elastic sheet has an arc-shaped design.

5. The UV-resistant outdoor cold-resistant power cable adaptable to day and night temperature differences according to claim 1, characterized in that: The connecting boss has an I-shaped design and serves to fix it in place.

6. The UV-resistant outdoor cold-resistant power cable adaptable to day and night temperature differences according to claim 1, characterized in that: Each crest of the extended structure is fixedly connected to the cable sheath layer, and each trough of the extended structure is fixedly connected to the hexagonal cell.

7. The UV-resistant outdoor cold-resistant power cable adaptable to day and night temperature differences according to claim 1, characterized in that: The cable separator rings are evenly spaced about the outer wall of the UV ceramic coating, and the corrugated structure is symmetrical about the vertical central axis of the cable separator rings.

8. The UV-resistant outdoor cold-resistant power cable adaptable to day and night temperature differences according to claim 1, characterized in that: A first connecting block is fixedly connected to the connection between the hexagonal cell and the microcapsule elastic sheet, and a second connecting block is fixedly connected to the connection between the microcapsule elastic sheet and the polyurea sealed microcapsule.

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