Flame-retardant fire-resistant soft cable with cooling function for communication power supply and manufacturing method thereof

Abstract

The present application relates to a fire-retardant fire-resistant soft cable with cooling function for communication power supply and a manufacturing method thereof. The present application comprises a conductor assembly, the conductor assembly comprising an inner ventilation pipe and an insulated core wire wrapped around the outer periphery of the inner ventilation pipe, the insulated core wire comprising an inner conductor and an insulation layer extruded on the outer periphery of the inner conductor; a fire-retardant glass fiber layer wrapped around the outer periphery of the conductor assembly; an armor layer wrapped around the outer periphery of the fire-retardant glass fiber layer; the armor layer is formed by wrapping a rectangular tape in a spiral manner, and a second hole is uniformly distributed along the length direction on one side of the central axis of the rectangular tape, and a second ventilation hole is formed on the armor layer after the wrapping and forming; an outer conductor is arranged on the outer periphery of the armor layer, and has a tubular structure with a spiral wrinkle structure, and a plurality of third ventilation holes are arranged along the circumferential direction at each wave peak of the spiral wrinkle structure; and an outer sheath layer is arranged on the outer periphery of the outer conductor. The present application realizes the simultaneous cooling of the surface and the inside of the cable.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to flame-retardant and fire-resistant flexible cables for communication power supplies with cooling function and their manufacturing methods. Background Technology

[0002] Flame-retardant and fire-resistant flexible cables for communication power supplies typically consist of several main parts, including a conductor, insulation layer, fire-resistant layer, and outer sheath. They are mainly used in power transmission and distribution systems in industries such as communication stations, high-rise buildings, railways, and chemical plants. They are used as power connection lines for communication power distribution system equipment. The long-term operating temperature is 70℃~90℃, so the cables need to have excellent high temperature resistance, high flame retardancy, and fire resistance.

[0003] Due to the large number of devices and high temperatures in the computer room, and the fact that cables easily generate heat during prolonged operation, both the internal and external temperatures of the cables rise (sometimes the surface temperature can reach 50°C, and the internal temperature is even higher). High temperatures can degrade the performance of the cable insulation and sheath materials, leading to thermal deformation and high-temperature stress, which affects the cable's flame retardancy and fire resistance, creating safety hazards for cables used in high-temperature environments.

[0004] Currently, air conditioning is typically installed in computer rooms to achieve indoor cooling. However, the equipment in indoor computer rooms is concentrated and dense, and the actual temperature remains high due to the heat generated by the equipment. In addition, the cables are also densely packed in the limited space. Even if air conditioning is used, it can only reduce the surface temperature of the cables and cannot alleviate the high temperature inside the cables. The high temperature inside the cables increases the risk of cable use, affects the flame retardancy and fire resistance of the cables, and increases safety hazards. Summary of the Invention

[0005] Therefore, the present invention provides a flame-retardant and fire-resistant flexible cable for communication power supply with cooling function and a method for manufacturing the same, so as to achieve simultaneous cooling of the cable surface and interior.

[0006] To solve the above-mentioned technical problems, the present invention provides a flame-retardant and fire-resistant flexible cable for communication power supply with cooling function, comprising:

[0007] A conductor assembly, comprising an inner ventilation duct and an insulated core wire wrapped around the outer periphery of the inner ventilation duct, the insulated core wire comprising an inner conductor and an insulating layer extruded over the inner conductor; wherein, four sets of ventilation assemblies are evenly spaced along the circumference of the inner ventilation duct, each set of ventilation assemblies comprising a plurality of first ventilation holes evenly spaced along the axial direction;

[0008] A flame-retardant fiberglass layer is wrapped around the outer periphery of the conductor assembly;

[0009] An armor layer is wrapped around the outer periphery of the flame-retardant fiberglass layer; wherein, the armor layer is formed by wrapping a rectangular strip in a spiral manner, and a second hole is provided on one side of the central axis along the length direction of the rectangular strip, which is evenly spaced along the length direction. After the wrapping is formed, the second hole forms a second ventilation hole distributed in four directions along the circumference on the armor layer.

[0010] An outer conductor is disposed on the outer periphery of the armor layer. The outer conductor is a tubular structure with a spiral wrinkled structure, and a plurality of third ventilation holes arranged circumferentially are provided at each crest of the spiral wrinkled structure.

[0011] An outer sheath layer is disposed on the outer periphery of the outer conductor;

[0012] The two ends of the internal ventilation duct are respectively configured as a sealing end and an air extraction end;

[0013] A gap is formed between the armor layer and the outer conductor on the side near the sealing end, allowing air to pass through.

[0014] The extraction end is used to communicate with the extraction device. By extracting air, a pressure difference is formed in the cable to drive the gas to enter the cable interior along the gap. The air contacts the outer sheath layer through the third ventilation hole and flows axially along the trough direction of the spiral corrugated structure. It enters the conductor assembly through the gap between the second ventilation hole and the flame-retardant fiberglass layer, and then enters the inner ventilation pipe through the first ventilation hole.

[0015] In one embodiment of the present invention, the internal ventilation duct is a copper tube formed by welding a first copper strip. The first copper strip is provided with four rows of first holes evenly spaced along the length direction. Each of the first holes is configured such that the ventilation components are evenly distributed in four groups along the circumference of the internal ventilation duct.

[0016] In one embodiment of the present invention, the thickness of the first copper strip is 0.3mm-0.5mm.

[0017] In one embodiment of the present invention, the first hole is a circular hole with a diameter of 2.0mm-5.0mm, and the distance between the edge of the first hole near the long side of the copper strip and the long side of the copper strip is not less than 5mm.

[0018] In one embodiment of the present invention, the rectangular strip is a galvanized steel strip with a thickness of 0.2mm-0.5mm, the distance between the edge of each second hole and the long side of the rectangular strip is not less than 5mm, the second hole is a round hole with a diameter of 2.0mm-5.0mm, and the distance between adjacent second holes is not less than twice the diameter of the second hole.

[0019] In one embodiment of the present invention, the rectangular strip is wrapped in a left-hand spiral, with a wrapping overlap of 15%-20%. During wrapping, the second holes are arranged in a spiral pattern of 30°-45° so that after the wrapping is formed, the second holes form second ventilation holes distributed in all four directions around the armor layer.

[0020] In one embodiment of the present invention, the outer conductor is formed by welding a second copper strip into a copper tube, and then forming a spiral wrinkled structure by corrugation.

[0021] In one embodiment of the invention, slots are formed on all four sides of each crest of the spiral wrinkle structure by milling to form the third ventilation hole; wherein the slots are configured as follows:

[0022] The groove width is 1 / 20 to 1 / 10 of the diameter of the outer conductor;

[0023] The length of the groove shall not exceed the width of the wave crest and shall not exceed 1 / 4 of the circumference of the wave crest.

[0024] The groove depth is 50%-70% of the outer conductor wall thickness;

[0025] The spacing between slots shall not be less than three times the slot width;

[0026] The groove shape adopts a rounded transition with a radius of not less than 0.5mm.

[0027] In one embodiment of the present invention, the thickness of the second copper strip is 0.2mm-0.3mm.

[0028] This invention also provides a method for manufacturing a flame-retardant and fire-resistant flexible cable for communication power supplies with cooling function, comprising:

[0029] Multiple strands of annealed soft copper wire are bundled into strands on a wire bundling machine in a left- or right-direction manner with a predetermined pitch; multiple strands are then stranded into an inner conductor on a tube stranding machine or cage stranding machine in a left- or right-direction manner with a predetermined pitch; cable insulation material is extruded onto the inner conductor through an extruder to form an insulation layer, thus obtaining an insulated core wire;

[0030] A first copper strip is provided, and four rows of first holes are punched on the first copper strip at uniform intervals along the length direction; wherein, the thickness of the first copper strip is 0.3mm-0.5mm, the first holes are round holes with a diameter of 2.0mm-5.0mm, and the distance between the edge of the first hole near the long side of the first copper strip and the long side of the first copper strip is not less than 5mm;

[0031] The first copper strip after punching is precision cut and welded into a copper tube to obtain an inner ventilation tube. The first holes form four sets of ventilation components evenly spaced along the circumference on the inner ventilation tube. The ventilation components are evenly spaced along the circumference of the inner ventilation tube in four sets. Each set of ventilation components includes a plurality of first ventilation holes evenly spaced along the axial direction.

[0032] The insulated core wire is wrapped around the outer periphery of the inner ventilation duct to form a conductor assembly;

[0033] High flame-retardant fiberglass tape is wrapped around the outer periphery of the conductor assembly to form a flame-retardant fiberglass layer;

[0034] A rectangular strip is provided and punched to form second holes evenly spaced along the length direction on one side of the central axis of the rectangular strip; wherein the rectangular strip is a galvanized steel strip with a thickness of 0.2mm-0.5mm, the distance between the edge of each second hole and the long side of the rectangular strip is not less than 5mm, the second hole is a round hole with a diameter of 2.0mm-5.0mm, and the distance between adjacent second holes is not less than twice the diameter of the second hole;

[0035] The rectangular strip is wrapped around the outer periphery of the flame-retardant fiberglass layer in a left-hand spiral manner using an armoring machine to form an armor layer. The wrapping overlap rate is 15%-20%, and the second holes are arranged in a spiral pattern of 30°-45° during wrapping so that the second holes form second ventilation holes distributed in four directions around the circumference on the armor layer after the wrapping is formed.

[0036] A second copper strip is provided, which is then welded into a copper tube on the outer periphery of the armor layer and then corrugated by a corrugating equipment to form a tubular structure with a spiral corrugated structure as an outer conductor; wherein the thickness of the second copper strip is 0.2mm-0.3mm;

[0037] Slots are milled on all four sides of each crest of the spiral corrugated structure of the outer conductor to form a plurality of third ventilation holes arranged circumferentially; wherein, the width of the slot is 1 / 20-1 / 10 of the diameter of the outer conductor, the slot length is not greater than the crest width and not greater than 1 / 4 of the crest circumference, the slot depth is 50%-70% of the wall thickness of the outer conductor, the slot spacing is not less than 3 times the slot width, and the slot shape adopts a rounded transition with a radius of not less than 0.5mm;

[0038] An outer sheath layer is extruded to form the outer periphery of the outer conductor;

[0039] The two ends of the inner ventilation duct are respectively configured as a sealing end and an air extraction end. A plug is installed at the sealing end to achieve a seal, and an interface for communication with an air extraction device is provided at the air extraction end. A gap is formed between the armor layer and the outer conductor near the sealing end to allow air to flow into the cable. When the air extraction device is working, a pressure difference is formed inside the cable through the air extraction end, driving outside air to enter the cable through the gap. The air contacts the outer sheath layer through the third ventilation hole and flows axially along the trough direction of the spiral corrugated structure. It then enters the conductor assembly through the gap between the second ventilation hole and the flame-retardant fiberglass layer, and finally enters the inner ventilation duct through the first ventilation hole.

[0040] The technical solution of the present invention has the following advantages compared with the prior art:

[0041] The present invention relates to a flame-retardant and fire-resistant flexible cable for communication power supplies with cooling function and its manufacturing method. Through a multi-stage ventilation hole structure consisting of an inner ventilation duct, an armor layer, and an outer conductor, a cooling and ventilation path is formed that connects the inside and outside of the cable. After the extraction end is connected to the extraction device, a pressure difference is created inside the cable. Outside air enters the cable through gaps on the sealed end side, sequentially passing through the third ventilation hole at the outer conductor crest, the second ventilation hole in the armor layer, and the interlayer gap of the flame-retardant fiberglass layer into the conductor assembly. It then enters the inner ventilation duct through the first ventilation hole, thus forming a continuous heat exchange cycle inside the cable. This structure not only reduces the surface temperature of the outer sheath layer but also directly reduces the temperature rise of the conductor assembly and its surrounding layers. It avoids the problem that traditional methods relying solely on air conditioning in the computer room to cool the cable surface are insufficient to suppress the high internal temperature of the cable. This reduces the risk of failure such as thermal deformation of the insulation material, high-temperature pressure creep, and sheath softening, thereby improving long-term operational reliability.

[0042] The armor layer of this invention is formed by spirally wrapping a perforated rectangular strip. The second perforation is arranged in a 30°-45° spiral pattern during wrapping, forming second ventilation holes distributed circumferentially on all four sides of the armor layer after wrapping. This allows gas to enter or escape from multiple directions around the cable. The outer conductor has multiple third ventilation holes at each crest of its spiral corrugated structure, further dispersing the gas entry and exit points circumferentially. This circumferential dispersion of the second and third ventilation holes significantly reduces uneven heat dissipation and hotspot accumulation caused by traditional single-sided or partial opening structures, delaying cracking, delamination, and aging caused by uneven heating and cooling.

[0043] The outer conductor of this invention adopts a spiral corrugated tubular structure, with the troughs naturally forming axially extending airflow channels. Air entering the area between the outer conductor and the outer sheath through the third ventilation hole can flow axially along the trough direction, continuously carrying away heat from the entire cable section. This structure enhances the axial transport capacity of airflow without significantly increasing the outer diameter and weight, improving the overall heat dissipation effect under long-distance cable laying conditions.

[0044] The present invention provides a flame-retardant fiberglass layer on the outer periphery of the conductor assembly. The flame-retardant fiberglass layer has high temperature resistance and fire insulation properties, which can maintain structural integrity and inhibit the spread of flames in flame or high temperature environments.

[0045] The internal ventilation duct of this invention is formed by punching holes in a first copper strip and then welding it. Copper has good thermal conductivity, which can quickly transfer heat from the conductor components to the wall of the internal ventilation duct, achieving more efficient convection heat transfer in conjunction with the first ventilation holes. At the same time, the process of punching, precision cutting, and welding copper strip into a duct is mature, with high dimensional consistency and batch stability.

[0046] The manufacturing method of this invention consists of steps such as wire bundling, stranding, insulation extrusion, copper strip punching, welding into tubes, wrapping into cables, fiberglass wrapping, steel strip punching, armor wrapping, copper strip welding and corrugating, corrugation, sheath extrusion, end sealing and air extraction interface configuration. These are all convenient combinations of processes, which allows the production process to be standardized. Attached Figure Description

[0047] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0048] Figure 1 This is a cross-sectional view of the flame-retardant and fire-resistant flexible cable for communication power supply with cooling function according to the present invention.

[0049] Figure 2 This is a longitudinal sectional view of the flame-retardant and fire-resistant flexible cable for communication power supply with cooling function according to the present invention.

[0050] Figure 3 This is a schematic diagram of the structure of the first copper strip of the present invention.

[0051] Figure 4 This is a front view structural diagram of the internal ventilation duct of the present invention.

[0052] Figure 5 This is a schematic diagram of the rectangular strip structure of the present invention.

[0053] Figure 6 This is a front view schematic diagram of the rectangular strip wrapped around the structure of the present invention.

[0054] Figure 7 This is a schematic diagram of the structure of the second copper strip of the present invention.

[0055] Figure 8 This is a schematic diagram of the structure of the outer conductor with a spiral wrinkle structure according to the present invention.

[0056] Figure 9 This is a flowchart illustrating the manufacturing method of a flame-retardant and fire-resistant flexible cable for communication power supplies with cooling function, as described in this invention.

[0057] Explanation of reference numerals on the accompanying drawings:

[0058] 1. Internal ventilation duct; 11. Ventilation assembly; 111. First ventilation hole; 12. First copper strip; 121. First hole;

[0059] 2. Insulated core wire; 21. Inner conductor; 22. Insulation layer;

[0060] 3. Flame-retardant fiberglass layer;

[0061] 4. Armor layer; 41. Rectangular strip; 411. Second hole; 42. Second ventilation hole;

[0062] 5. Outer conductor; 51. Second copper strip; 511. Spiral corrugated structure; 512. Third ventilation hole; 513. Slot;

[0063] 6. Outer sheath layer. Detailed Implementation

[0064] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0065] In this invention, when directions (up, down, left, right, front, and back) are described, it is only for the convenience of describing the technical solution of this invention, and does not indicate or imply that the technical features referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this invention.

[0066] In this invention, "several" means one or more, "multiple" means two or more, "greater than," "less than," "exceeding," etc., are understood to exclude the stated number; "above," "below," "within," etc., are understood to include the stated number. In the description of this invention, the terms "first" and "second" are used only to distinguish technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0067] In this invention, unless otherwise explicitly defined, the terms "setting," "installing," and "connecting" should be interpreted broadly. For example, they can refer to a direct connection or an indirect connection through an intermediate medium; a fixed connection, a detachable connection, or an integrally formed connection; a mechanical connection, an electrical connection, or a connection capable of mutual communication; or the internal connection of two components or the interaction between two components. Those skilled in the art can reasonably determine the specific meaning of the above terms in this invention based on the specific content of the technical solution.

[0068] Reference Figure 1 , Figure 2 , Figure 4 , Figure 6 , Figure 8 As shown, this embodiment provides a flame-retardant and fire-resistant flexible cable for communication power supplies with cooling function, comprising:

[0069] A conductor assembly, comprising an inner ventilation duct 1 and an insulated core wire 2 wrapped around the outer periphery of the inner ventilation duct 1, wherein the insulated core wire 2 comprises an inner conductor 21 and an insulating layer 22 extruded outside the inner conductor 21; wherein, four sets of ventilation components 11 are evenly spaced along the circumference on the inner ventilation duct 1, and each set of ventilation components 11 comprises a plurality of first ventilation holes 111 evenly spaced along the axial direction;

[0070] A flame-retardant fiberglass layer 3 is wrapped around the outer periphery of the conductor assembly;

[0071] The armor layer 4 is wrapped around the outer periphery of the flame-retardant fiberglass layer 3; wherein, the armor layer 4 is formed by wrapping a rectangular strip 41 in a spiral manner, and a second hole 411 is provided on one side of the central axis along the length direction of the rectangular strip 41, which is evenly spaced along the length direction. After the second hole 411 is formed, a second ventilation hole 42 is formed on the armor layer 4 along the four sides of the circumference.

[0072] The outer conductor 5 is disposed on the outer periphery of the armor layer 4. The outer conductor 5 is a tubular structure with a spiral wrinkle structure 511, and a plurality of third ventilation holes 512 arranged circumferentially are provided at each crest of the spiral wrinkle structure 511.

[0073] The outer sheath layer 6 is disposed on the outer periphery of the outer conductor 5;

[0074] The two ends of the internal ventilation pipe 1 are respectively configured as a sealing end (by blocking it with a plug) and an exhaust end;

[0075] A gap is formed between the armor layer 4 and the outer conductor 5 near the sealing end, allowing air to pass through.

[0076] The extraction end is used to communicate with the extraction device. By extracting air, a pressure difference is formed inside the cable to drive gas into the cable interior along the gap. The air contacts the outer sheath layer 6 through the third ventilation hole 512 and cools the surface of the outer sheath layer 6. At the same time, it flows axially along the trough direction of the spiral corrugated structure 511, enters the conductor assembly through the gap between the second ventilation hole 42 and the flame-retardant glass fiber layer 3, and then enters the inner ventilation pipe 1 through the first ventilation hole 111, thereby achieving a cooling effect inside and outside the cable, and also achieving physical cooling between the various cable structural layers.

[0077] Cooling the internal structure of the cable with gas ensures the performance of the cable's insulation and sheath materials, mitigating potential thermal deformation and high-temperature pressure issues. Since the heat generated during cable use can affect its flame retardancy and fire resistance, cooling the internal structure with gas ensures these properties during use, reducing potential safety hazards associated with using cables in high-temperature environments.

[0078] In one embodiment, refer to Figure 3 As shown, the inner ventilation duct 1 is a copper tube welded from a first copper strip 12. The first copper strip 12 is provided with four rows of first holes 121 evenly spaced along the length direction. Each of the first holes 121 is configured such that the ventilation components 11 are evenly distributed in four groups along the circumference of the inner ventilation duct 1.

[0079] In one embodiment, the thickness of the first copper strip 12 is 0.3mm-0.5mm.

[0080] In one embodiment, the first hole 121 is a circular hole with a diameter of 2.0mm-5.0mm (set according to the cable specifications), and the distance between the edge of the first hole 121 near the long side of the copper strip and the long side of the copper strip is not less than 5mm.

[0081] In one embodiment, refer to Figure 5 As shown, the rectangular strip 41 is a galvanized steel strip with a thickness of 0.2mm-0.5mm. The distance between the edge of each second hole 411 and the long side of the rectangular strip 41 is not less than 5mm. The second hole 411 is a round hole with a diameter of 2.0mm-5.0mm (set according to the cable specifications). The distance between adjacent second holes 411 is not less than twice the diameter of the second hole 411.

[0082] The cable is equipped with a galvanized steel strip armor layer 4 with four openings. The second hole 411 is circular in shape. The stress concentration coefficient at the edge of the circular hole is much lower than that of the square hole, which significantly reduces the risk of cracks around the hole, extends the fatigue life of the armor layer 4, and ensures that the gas extracted by the internal ventilation copper pipe can flow out to the outer structure to achieve the purpose of cooling.

[0083] In one embodiment, the rectangular strip 41 is wrapped in a left-hand spiral, with a wrapping overlap of 15%-20%. During wrapping, the second holes 411 are arranged in a spiral pattern of 30°-45° to ensure the protective effect of the armor layer 4 while forming second ventilation holes 42 distributed in the four circumferential directions on the armor layer 4 after the wrapping is formed.

[0084] In one embodiment, refer to Figure 8As shown, the outer conductor 5 is formed by welding the second copper strip 51 into a copper tube, and then forming a spiral corrugated structure 511 through corrugation. The spiral corrugated structure 511 allows air to circulate along its troughs to achieve a cooling effect for the entire cable.

[0085] In one embodiment, each crest of the spiral wrinkle structure 511 is milled to form slots 513 on all four sides to form the third ventilation hole 512, achieving the effect of opening on all four sides, so that the gas extracted from the inside can smoothly reach the outer sheath layer 6.

[0086] The slot 513 is configured as follows:

[0087] The groove width is 1 / 20 to 1 / 10 of the diameter of the outer conductor 5;

[0088] The length of the groove should not exceed the width of the wave crest and should not exceed 1 / 4 of the circumference of the wave crest to prevent structural weakening.

[0089] The groove depth is 50%-70% of the wall thickness of the outer conductor 5, ensuring that the remaining thickness meets the mechanical strength requirements;

[0090] The spacing between slots should be no less than three times the slot width to avoid stress concentration.

[0091] The groove shape adopts a rounded transition with a radius of not less than 0.5mm. By using a rounded transition instead of a right angle, the risk of cracking is reduced.

[0092] In one embodiment, the thickness of the second copper strip 51 is 0.2mm-0.3mm.

[0093] Reference Figure 9 As shown, this embodiment also provides a method for manufacturing a flame-retardant and fire-resistant flexible cable for communication power supplies with cooling function, including:

[0094] Wire bundling process: Multiple strands of annealed soft copper wires are bundled into strands on a wire bundling machine in a left- or right-hand direction with a predetermined pitch;

[0095] Stranding process: Multiple strands of wire are stranded into an inner conductor 21 by a predetermined pitch in the left or right direction on a tube stranding machine or cage stranding machine;

[0096] Insulation process: The cable insulation material is extruded onto the inner conductor 21 through an extruder to form an insulation layer 22, thereby obtaining the insulated core wire 2;

[0097] Punching process: A smooth first copper strip 12 is provided, and four rows of first holes 121 are punched on the first copper strip 12 at even intervals along the length direction; wherein, the thickness of the first copper strip 12 is 0.3mm-0.5mm, the first hole 121 is a round hole with a diameter of 2.0mm-5.0mm, and the distance between the edge of the first hole 121 near the long side of the first copper strip 12 and the long side of the first copper strip 12 is not less than 5mm;

[0098] Welding process: The first copper strip 12 after punching is precision cut and welded into a copper tube to obtain the inner ventilation tube 1. The first holes 121 form four sets of ventilation components 11 evenly spaced along the circumference on the inner ventilation tube 1. The ventilation components 11 are evenly spaced along the circumference of the inner ventilation tube 1 in four sets. Each set of ventilation components 11 includes a plurality of first ventilation holes 111 evenly spaced along the axial direction.

[0099] Insulation wrapping process: The insulating core wire 2 is wrapped around the outer periphery of the inner ventilation pipe 1 to form a conductor assembly;

[0100] The semi-finished product inspection process is carried out, and subsequent steps are carried out after the inspection is qualified.

[0101] High flame-retardant fiberglass tape wrapping: High flame-retardant fiberglass tape is wrapped around the outer periphery of the conductor assembly to form a flame-retardant fiberglass layer 3;

[0102] Punching process: A rectangular strip 41 is provided and punched to form second holes 411 evenly spaced along the length direction on one side of the central axis of the rectangular strip 41; wherein, the rectangular strip 41 is a galvanized steel strip with a thickness of 0.2mm-0.5mm, the distance between the edge of each second hole 411 and the long side of the rectangular strip 41 is not less than 5mm, the second hole 411 is a round hole with a diameter of 2.0mm-5.0mm, and the distance between adjacent second holes 411 is not less than twice the diameter of the second hole 411;

[0103] Armoring process: The rectangular strip 41 is wrapped around the outer periphery of the flame-retardant fiberglass layer 3 in a left-hand spiral manner using an armoring machine to form an armoring layer 4. The wrapping overlap rate is 15%-20%, and during wrapping, the second holes 411 are arranged in a spiral pattern of 30°-45° so that after the wrapping is formed, the second holes 411 form second ventilation holes 42 distributed in four directions around the circumference on the armoring layer 4. During the wrapping process, the wrapping tension should be reduced (usually reduced by 10%-15%) to avoid deformation of the edges of the second holes 411.

[0104] Outer conductor 5 corrugated welding: A smooth second copper strip 51 is provided. After the second copper strip 51 is welded into a copper tube on the outer periphery of the armor layer 4, it is corrugated by a corrugating equipment to form a tubular structure with a spiral corrugated structure 511 as the outer conductor 5; wherein, the thickness of the second copper strip 51 is 0.2mm-0.3mm.

[0105] Slotting of outer conductor 5: Slots 513 are formed on the four sides of each crest of the spiral corrugated structure 511 of the outer conductor 5 by milling, so as to form a plurality of third ventilation holes 512 arranged circumferentially; wherein, the slot width of the slot 513 is 1 / 20-1 / 10 of the diameter of the outer conductor 5, the slot length is not greater than the crest width and not greater than 1 / 4 of the crest circumference, the slot depth is 50%-70% of the wall thickness of the outer conductor 5, the slot spacing is not less than 3 times the slot width, and the slot shape adopts a rounded transition with a radius of not less than 0.5mm;

[0106] An outer sheath layer 6 is extruded to form the outer periphery of the outer conductor 5;

[0107] Sheathing process: The two ends of the inner ventilation pipe 1 are respectively configured as a sealing end and an air extraction end. A plug is installed on the sealing end to achieve a seal, and an interface for communication with the air extraction device is provided on the air extraction end. A gap is formed between the armor layer 4 and the outer conductor 5 near the sealing end to allow air to flow through. When the air extraction device is working, a pressure difference is formed inside the cable through the air extraction end, driving outside air to enter the cable through the gap. The air contacts the outer sheath layer 6 through the third ventilation hole 512 and flows axially along the trough direction of the spiral corrugated structure 511. Then, it enters the conductor assembly through the gap between the second ventilation hole 42 and the flame-retardant fiberglass layer 3, and finally enters the inner ventilation pipe 1 through the first ventilation hole 111.

[0108] The cable employs a method of plugging one end and evacuating the other. This evacuation removes gas molecules (including water vapor and oxygen) from the inner ventilation duct 1, maintaining the insulation performance of the internal structural layers. Heat convection within the cable is completely suppressed under evacuation conditions, relying solely on heat conduction from the inner ventilation duct 1 wall. This prevents axial temperature rise caused by gas flow, delays the thermo-oxidative aging of the cable insulation material, and effectively controls electrochemical corrosion (due to the absence of oxygen and water vapor). The entire cable structure, through the specially designed inner ventilation duct 1, armor layer 4, and outer conductor 5 within the structural layers, and the method of plugging one end and evacuating the other, allows air to circulate smoothly within the cable, achieving physical cooling between the various structural layers and externally. Simultaneously, it delays the thermo-oxidative aging of the cable insulation material and effectively controls electrochemical corrosion.

[0109] Finally, it should be noted that the above specific embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to examples, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A flame-retardant and fire-resistant flexible cable for communication power supplies with cooling function, characterized in that, include: The conductor assembly includes an inner ventilation duct (1) and an insulated core wire (2) wrapped around the outer periphery of the inner ventilation duct (1). The insulated core wire (2) includes an inner conductor (21) and an insulation layer (22) extruded outside the inner conductor (21). The inner ventilation duct (1) is provided with four sets of ventilation components (11) evenly spaced along the circumference. Each set of ventilation components (11) includes a plurality of first ventilation holes (111) evenly spaced along the axial direction. A flame-retardant fiberglass layer (3) is wrapped around the outer periphery of the conductor assembly; An armor layer (4) is wrapped around the outer periphery of the flame-retardant fiberglass layer (3); wherein, the armor layer (4) is formed by wrapping a rectangular strip (41) in a spiral manner, and a second hole (411) is provided on one side of the central axis along the length direction of the rectangular strip (41), which is evenly spaced along the length direction. After the second hole (411) is formed, a second ventilation hole (42) is formed on the armor layer (4) in a circumferential direction. An outer conductor (5) is disposed on the outer periphery of the armor layer (4). The outer conductor (5) is a tubular structure with a spiral wrinkle structure (511), and a plurality of third ventilation holes (512) are provided at each crest of the spiral wrinkle structure (511) along the circumferential direction. An outer sheath layer (6) is disposed on the outer periphery of the outer conductor (5); The two ends of the internal ventilation pipe (1) are respectively configured as a sealing end and an air extraction end; A gap is formed between the armor layer (4) and the outer conductor (5) near the sealing end, allowing air to pass through; The extraction end is used to communicate with the extraction device. By extracting air, a pressure difference is formed in the cable to drive the gas to enter the cable through the gap. The air contacts the outer sheath layer (6) through the third ventilation hole (512) and flows axially along the trough direction of the spiral wrinkle structure (511). It enters the conductor assembly through the gap between the second ventilation hole (42) and the flame-retardant fiberglass layer (3), and then enters the inner ventilation pipe (1) through the first ventilation hole (111).

2. The flame-retardant and fire-resistant flexible cable for communication power supply with cooling function according to claim 1, characterized in that, The internal ventilation duct (1) is a copper tube formed by welding a first copper strip (12). The first copper strip (12) has four rows of first holes (121) evenly spaced along the length direction. Each of the first holes (121) is configured such that the ventilation components (11) are evenly distributed in four groups along the circumference of the internal ventilation duct (1).

3. The flame-retardant and fire-resistant flexible cable for communication power supply with cooling function according to claim 2, characterized in that, The thickness of the first copper strip (12) is 0.3mm-0.5mm.

4. The flame-retardant and fire-resistant flexible cable for communication power supply with cooling function according to claim 2, characterized in that, The first hole (121) is a round hole with a diameter of 2.0mm-5.0mm. The distance between the edge of the first hole (121) near the long side of the copper strip and the long side of the copper strip is not less than 5mm.

5. The flame-retardant and fire-resistant flexible cable for communication power supply with cooling function according to claim 1, characterized in that, The rectangular strip (41) is a galvanized steel strip with a thickness of 0.2mm-0.5mm. The distance between the edge of each second hole (411) and the long side of the rectangular strip (41) is not less than 5mm. The second hole (411) is a round hole with a diameter of 2.0mm-5.0mm. The distance between adjacent second holes (411) is not less than twice the diameter of the second hole (411).

6. The flame-retardant and fire-resistant flexible cable for communication power supply with cooling function according to claim 1, characterized in that, The rectangular strip (41) is wrapped in a left-hand spiral, with a wrapping overlap of 15%-20%. During wrapping, the second hole (411) is arranged in a spiral pattern of 30°-45° so that the second hole (411) forms a second ventilation hole (42) distributed in the four circumferential directions on the armor layer (4) after the wrapping is formed.

7. The flame-retardant and fire-resistant flexible cable for communication power supply with cooling function according to claim 1, characterized in that, The outer conductor (5) is formed by welding the second copper strip (51) into a copper tube and then forming a spiral wrinkled structure (511) through corrugation.

8. The flame-retardant and fire-resistant flexible cable for communication power supply with cooling function according to claim 7, characterized in that, Each crest of the spiral wrinkle structure (511) has a slot (513) formed on all four sides by milling to form the third ventilation hole (512); wherein the slot (513) is configured as follows: The groove width is 1 / 20 to 1 / 10 of the diameter of the outer conductor (5); The length of the groove shall not exceed the width of the wave crest and shall not exceed 1 / 4 of the circumference of the wave crest. The groove depth is 50%-70% of the wall thickness of the outer conductor (5); The spacing between slots shall not be less than three times the slot width; The groove shape adopts a rounded transition with a radius of not less than 0.5mm.

9. The flame-retardant and fire-resistant flexible cable for communication power supply with cooling function according to claim 7, characterized in that, The thickness of the second copper strip (51) is 0.2mm-0.3mm.

10. A method for manufacturing a flame-retardant and fire-resistant flexible cable for communication power supplies with cooling function, characterized in that, include: Multiple strands of annealed soft copper wires are bundled into strands on a wire bundling machine in a left- or right-direction manner using a predetermined pitch. Multiple strands are stranded into an inner conductor (21) in a left- or right-hand direction using a predetermined pitch on a tube stranding machine or a cage stranding machine; cable insulation material is extruded onto the inner conductor (21) through an extruder to form an insulation layer (22), thus obtaining an insulated core wire (2). A first copper strip (12) is provided, and four rows of first holes (121) are punched on the first copper strip (12) at even intervals along the length direction; wherein, the thickness of the first copper strip (12) is 0.3mm-0.5mm, the first hole (121) is a round hole with a diameter of 2.0mm-5.0mm, and the distance between the edge of the first hole (121) near the long side of the first copper strip (12) and the long side of the first copper strip (12) is not less than 5mm; The first copper strip (12) after punching is precision cut and welded into a copper tube to obtain an inner ventilation tube (1). The first hole (121) forms four sets of ventilation components (11) evenly spaced along the circumference on the inner ventilation tube (1). The ventilation components (11) are evenly spaced along the circumference of the inner ventilation tube (1) in four sets. Each set of ventilation components (11) includes a plurality of first ventilation holes (111) evenly spaced along the axial direction. The insulated core wire (2) is wrapped around the outer periphery of the inner ventilation pipe (1) to form a conductor assembly; A high flame-retardant fiberglass tape is wrapped around the outer periphery of the conductor assembly to form a flame-retardant fiberglass layer (3). A rectangular strip (41) is provided and punched to form second holes (411) evenly spaced along the length direction on one side of the central axis of the rectangular strip (41); wherein the rectangular strip (41) is a galvanized steel strip with a thickness of 0.2mm-0.5mm, the diameter of the second holes (411) is 2.0mm-5.0mm, the distance between the edge of each second hole (411) and the long side of the rectangular strip (41) is not less than 5mm, the second holes (411) are round holes, and the distance between adjacent second holes (411) is not less than twice the diameter of the second hole (411); The rectangular strip (41) is wrapped around the outer periphery of the flame-retardant fiberglass layer (3) in a left-hand spiral manner using an armoring machine to form an armor layer (4). The wrapping overlap rate is 15%-20%, and the second holes (411) are arranged in a spiral pattern of 30°-45° during wrapping, so that the second holes (411) form second ventilation holes (42) distributed in four directions around the circumference on the armor layer (4) after the wrapping is formed. A second copper strip (51) is provided. After the second copper strip (51) is welded into a copper tube on the outer periphery of the armor layer (4), it is corrugated by a corrugating equipment to form a tubular structure with a spiral corrugated structure (511) as an outer conductor (5); wherein, the thickness of the second copper strip (51) is 0.2mm-0.3mm. Slots (513) are formed on the four sides of each crest of the spiral wrinkle structure (511) of the outer conductor (5) by milling, so as to form a plurality of third ventilation holes (512) arranged in the circumferential direction; wherein, the slot width of the slot (513) is 1 / 20-1 / 10 of the diameter of the outer conductor (5), the slot length is not greater than the crest width and not greater than 1 / 4 of the crest circumference, the slot depth is 50%-70% of the wall thickness of the outer conductor (5), the slot spacing is not less than 3 times the slot width, and the slot shape adopts a circular arc transition with a circular arc radius of not less than 0.5mm; An outer sheath layer (6) is formed by extrusion around the outer conductor (5); The two ends of the inner ventilation pipe (1) are respectively configured as a sealing end and an air extraction end. A plug is installed on the sealing end to achieve sealing, and an interface for communicating with the air extraction device is provided on the air extraction end. A gap is formed between the armor layer (4) and the outer conductor (5) near the sealing end to allow communication with the outside air. Thus, when the air extraction device is working, a pressure difference is formed inside the cable through the air extraction end, driving the outside air to enter the cable through the gap. The air contacts the outer sheath layer (6) through the third ventilation hole (512) and flows axially along the trough direction of the spiral corrugated structure (511). It then enters the conductor assembly through the gap between the second ventilation hole (42) and the flame-retardant fiberglass layer (3), and finally enters the inner ventilation pipe (1) through the first ventilation hole (111).

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