Composite cable and method for manufacturing the same

Abstract

The application belongs to the technical field of cable manufacturing, and specifically discloses a composite cable and a preparation method thereof, which comprises an inner sheath, the inner sheath is internally provided with connecting sleeves, the connecting sleeves are internally provided with connecting cores, the inner sheath is internally provided with first filling layers at the outer walls of the connecting sleeves, the outer wall of the inner sheath is circumferentially provided with control cores, the outer wall of the inner sheath is provided with an insulating layer, the control cores are located in the insulating layer, the gap between the control cores and the insulating layer is filled with a second filling layer, the second filling layer is connected with the outer wall of the inner sheath, the middle part of the outer wall of the insulating layer is provided with a reinforcing shielding layer, and the outer wall of the insulating layer is provided with a buffer sleeve. The application improves the mechanical reliability, anti-interference ability and service life of the cable in a poor environment.

Description

Technical Field

[0001] This invention belongs to the field of cable manufacturing technology, and specifically discloses a composite cable and its preparation method. Background Technology

[0002] As carriers of electrical energy, signals, and data transmission, wires and cables are core infrastructure of modern industry and the information society. To meet the multifunctional needs of complex application scenarios, composite cables have emerged. Composite cables integrate power transmission cores, signal control cores, and fiber optic communication units into one unit, protected by a unified sheath. They offer significant advantages such as simplified wiring, space saving, and convenient centralized management, and are widely used in industrial automation, new energy equipment, robotics, and high-end manufacturing.

[0003] During the laying and long-term use of cables, in order to maintain their positional stability and prevent loosening of connection points due to their own weight or external pulling, it is usually necessary to use fasteners such as clamps, clips, or cable ties to periodically fix the cables. For horizontally laid cables, however, the outer sheath of existing composite cables is mostly of a homogeneous structure with consistent mechanical properties along the length. Each fixing point constitutes a local stress concentration point. When the cable is subjected to fastening pressure at the clamp for a long time, accompanied by vibration or slight displacement caused by equipment operation, the outer sheath of the cable and the edge of the clamp will experience continuous friction and compression. This long-term local stress concentration and wear can easily lead to indentations, cracks, or even damage to the outer sheath, thereby threatening the insulation integrity, shielding effectiveness, and transmission performance of the internal functional units. Once the sheath is damaged, it will not only introduce moisture and dust, causing corrosion and short-circuit risks, but also often require shutdown for local repairs or complete replacement, resulting in high subsequent maintenance costs and production interruption losses. Summary of the Invention

[0004] The purpose of this invention is to solve the problems existing in the background art, and to propose a composite cable including an inner sheath, wherein each inner sheath is provided with a connecting sleeve, each connecting sleeve is provided with a connecting core, a first filling layer is provided in the inner sheath corresponding to the outer wall of the multiple connecting sleeves, control cores are provided circumferentially on the outer wall of the inner sheath, an insulation layer is provided on the outer wall of the inner sheath, multiple control cores are located inside the insulation layer, a second filling layer is filled in the gap between the control cores and the insulation layer, the second filling layer is connected to the outer wall of the inner sheath, a reinforcing shielding layer is provided in the middle of the outer wall of the insulation layer, and a buffer sleeve is provided on the outer wall of the insulation layer.

[0005] The outer wall of each buffer sleeve is provided with buffer blocks in a circumferential direction, and the outer wall of each buffer block is provided with an outer protective sleeve. The outer wall of the outer protective sleeve is provided with an reinforcing sleeve corresponding to the outer wall of the reinforcing shielding layer, and the outer wall of the outer protective sleeve is provided with a protective mechanism corresponding to the outer wall of the reinforcing sleeve.

[0006] The protective mechanism includes a protective sleeve, with sealing sleeves at both ends of the protective sleeve. The inner walls of the two sealing sleeves are in contact with the outer wall of the outer protective sleeve. The inner walls of the protective sleeve are provided with reinforcing ribs in the circumferential direction. The ends of the multiple reinforcing ribs are provided with flexible ribs. The outer walls of the two sealing sleeves are wrapped with spiral heat shrink tape.

[0007] Preferably, the connecting sleeve is made of polyvinyl chloride, the connecting wire core is made of multiple stranded wires, and the first filling layer and the second filling layer are both made of aluminum-plastic composite tape.

[0008] Preferably, the inner wall of the buffer sleeve has a stabilizing groove corresponding to the reinforcing shielding layer, the reinforcing shielding layer is located inside the stabilizing groove, the shape of the stabilizing groove is adapted to the shape of the reinforcing shielding layer, the buffer sleeve is a composite material structure, the inner layer of the buffer sleeve is made of silicone rubber, and the outer layer of the buffer sleeve is a highly wear-resistant insulating material.

[0009] Preferably, the protective sleeve is fitted onto the outer wall of the reinforcing sleeve, both ends of the protective sleeve are inclined, the shape of the inner wall of the protective sleeve is adapted to the shape of the outer wall of the reinforcing sleeve, both the protective sleeve and the sealing sleeve are arranged in a ring shape, and there are two sets of sealing sleeves.

[0010] Preferably, a first mounting strip is provided at one end of the protective sleeve and at one end of the two sealing sleeves, and a second mounting strip is provided at the other end of the protective sleeve and at the other end of the two sealing sleeves.

[0011] Preferably, both the first mounting strip and the second mounting strip are made of Velcro material, and the upper part of the first mounting strip and the lower part of the second mounting strip are bonded together.

[0012] Preferably, the plurality of reinforcing ribs and the plurality of flexible ribs are located around the outer wall of the reinforcing sleeve, the flexible ribs are all arranged in an inclined manner, and the plurality of flexible ribs are respectively located on both sides of the inner wall of the protective sleeve and connected.

[0013] A method for preparing a composite cable includes the following steps:

[0014] S1: The inner sheath and internal connecting cores provide an independent power transmission channel with reliable insulation; the first and second filling layers form a distributed shielding network while filling structural gaps, effectively suppressing electromagnetic interference between power and signal cores; when each aluminum-plastic composite tape is wrapped, its metal surface (aluminum layer) ensures its longitudinal electrical continuity through overlapping; after the cable is cabled, these aluminum-plastic composite tape shielding layers are reliably connected to the cable's main ground at the cable end through metal shielding leads or conductive connectors; finally, the control cores are circumferentially covered with an insulation layer to achieve reliable electrical isolation between high and low voltage units;

[0015] S2: Reinforcing shielding layers are set at intervals outside the insulation layer, and then the buffer sleeve is extruded and covered. During extrusion, the molten buffer material flows through the protruding reinforcing shielding layer and is squeezed and guided by it. After cooling, a matching stabilizing groove is formed in situ on the inner wall of the buffer sleeve, realizing the mechanical interlocking and stable fixation of the shielding layer. This structure, together with the externally covered reinforcing sleeve, constitutes the rigid reinforcing section of the cable.

[0016] S3: Install a protective mechanism on the vulnerable section of the cable: Position the protective sleeve and the sealing sleeves at both ends to the reinforcing sleeve of the outer sheath, and quickly lock them together with the first and second mounting strips using Velcro, so that the internal reinforcing ribs and flexible ribs form a three-dimensional protective net. Finally, wrap the spiral heat shrink tape around the joint between the sealing sleeve and the outer sheath and heat shrink it to achieve a permanent seal at the port.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] By intermittently setting reinforced shielding layers and external reinforcing sleeves in specific vulnerable sections of the cable's outer sheath, the reinforcing sleeves serve as dedicated mounting bases for the clamps. Their high-strength structure directly bears the fastening force, eliminating the squeezing and wear of the clamp edges on the outer sheath during traditional installation. Furthermore, the preset positions of the reinforcing sleeves provide visual guidance for installation, ensuring that they can be correctly activated every time, thus achieving precise protection.

[0019] The reinforcing ribs and flexible ribs inside the protective sleeve can efficiently absorb and disperse severe mechanical loads such as external impacts and compression. With the setting of the first mounting strip, the second mounting strip and the spiral heat shrink tape, the protective mechanism can be quickly installed, sealed and subsequently disassembled and replaced on site, which improves the convenience of maintenance and the reusability of components. The protective mechanism can also be activated as needed according to actual risks. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0021] Figure 2 This is an overall cross-sectional view of the cable of the present invention.

[0022] Figure 3 This is a schematic diagram of the connection structure between the connecting wire core and the first filling layer of the present invention.

[0023] Figure 4 This is a schematic diagram of the connection structure of the reinforcing sleeve of the present invention.

[0024] Figure 5 For the present invention Figure 4 A magnified structural diagram of A in the diagram.

[0025] Figure 6 This is a schematic diagram of the connection structure between the reinforced shielding layer and the reinforcing sleeve of the present invention.

[0026] Figure 7 This is a schematic diagram of the structure of the stabilizing groove of the present invention.

[0027] Figure 8 This is a schematic diagram of the connection structure between the first mounting strip and the second mounting strip of the present invention.

[0028] Figure 9 This is a schematic diagram of the installation structure of the reinforcing ribs and flexible ribs of the present invention.

[0029] Figure descriptions: 1. Inner sheath; 2. Connecting sleeve; 3. Connecting core; 4. First filler layer; 5. Control core; 6. Second filler layer; 7. Insulation layer; 8. Reinforced shielding layer; 9. Buffer sleeve; 10. Stabilizing groove; 11. Buffer block; 12. Outer sheath; 13. Reinforcing sleeve; 14. Protective sleeve; 15. Sealing sleeve; 16. First mounting strip; 17. Second mounting strip; 18. Reinforcing rib; 19. Flexible rib; 20. Spiral heat shrink tape. Detailed Implementation

[0030] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0031] Numerous specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the invention is not limited to the specific embodiments disclosed below.

[0032] like Figures 1-9 A composite cable and its manufacturing method are shown, comprising an inner sheath 1, with connecting sleeves 2 disposed inside the inner sheath 1, connecting cores 3 disposed inside the connecting sleeves 2, a first filling layer 4 disposed inside the inner sheath 1 corresponding to the outer walls of the multiple connecting sleeves 2, control cores 5 disposed circumferentially on the outer walls of the inner sheath 1, an insulation layer 7 sleeved on the outer walls of the inner sheath 1, multiple control cores 5 being located inside the insulation layer 7, a second filling layer 6 filling the gap between the control cores 5 and the insulation layer 7, the second filling layer 6 being connected to the outer walls of the inner sheath 1, a reinforced shielding layer 8 disposed in the middle of the outer walls of the insulation layer 7, a buffer sleeve 9 sleeved on the outer walls of the insulation layer 7, buffer blocks 11 disposed circumferentially on the outer walls of the buffer sleeves 9, an outer sheath 12 disposed on the outer walls of the multiple buffer blocks 11, an reinforcing sleeve 13 disposed on the outer walls of the outer sheath 12 corresponding to the outer walls of the reinforced shielding layer 8, and a protective mechanism disposed on the outer walls of the outer sheath 12 corresponding to the outer walls of the reinforcing sleeve 13.

[0033] The first filling layer 4 and the second filling layer 6 fill the gaps in the cable structure and form a distributed shielding network to suppress internal electromagnetic interference. The control core 5 is used to transmit control and signals. The insulation layer 7 provides basic electrical isolation. The reinforced shielding layer 8 provides enhanced electromagnetic shielding in vulnerable sections of the cable. The buffer block 11 disperses external pressure and provides primary shock resistance. The reinforcing sleeve 13 provides a dedicated mounting base for the cable clamp to withstand and disperse the fastening force. The protective mechanism provides removable additional mechanical protection in extreme environments.

[0034] like Figures 4-7 As shown: the connecting sleeve 2 is made of polyvinyl chloride material, the connecting wire core 3 is made of multiple wires twisted together, the first filling layer 4 and the second filling layer 6 are both made of aluminum-plastic composite tape material, the inner wall of the buffer sleeve 9 is provided with a stabilizing groove 10 corresponding to the reinforcing shielding layer 8, the reinforcing shielding layer 8 is located inside the stabilizing groove 10, the shape of the stabilizing groove 10 is adapted to the shape of the reinforcing shielding layer 8, the buffer sleeve 9 is a composite material structure, the inner layer of the buffer sleeve 9 is made of silicone rubber material, and the outer layer of the buffer sleeve 9 is a highly wear-resistant insulating material;

[0035] The matching structure between the stabilizing groove 10 and the reinforcing shielding layer 8 enables the mechanical limiting and anti-displacement fixation of the reinforcing shielding layer 8. The inner layer of the buffer sleeve 9 provides high elasticity buffering and stress absorption, while the outer layer of the buffer sleeve 9 is used to resist external wear and maintain electrical insulation integrity.

[0036] like Figures 8-9 As shown: The protective mechanism includes a protective sleeve 14, with sealing sleeves 15 at both ends. The inner walls of the two sealing sleeves 15 contact the outer wall of the outer protective sleeve 12. Reinforcing ribs 18 are circumferentially arranged on the inner wall of the protective sleeve 14, and flexible ribs 19 are provided at both ends of the multiple reinforcing ribs 18. Spiral heat-shrinkable tape 20 is wound around the outer walls of the two sealing sleeves 15. The protective sleeve 14 is fitted onto the outer wall of the reinforcing sleeve 13. The shapes of both ends of the protective sleeve 14 are inclined, and the shape of the inner wall of the protective sleeve 14 matches the shape of the outer wall of the reinforcing sleeve 13. Both the protective sleeve 14 and the sealing sleeves 15 are annular. The sealing sleeves 15 are configured in two sets. One end of the protective sleeve 14 and one end of the two sealing sleeves 15 are provided with a first mounting strip 16, and the other end of the protective sleeve 14 and the other end of the two sealing sleeves 15 are provided with a second mounting strip 17. Both the first mounting strip 16 and the second mounting strip 17 are made of Velcro material. The upper part of the first mounting strip 16 and the lower part of the second mounting strip 17 are bonded together. Multiple reinforcing ribs 18 and multiple flexible ribs 19 are located around the outer wall of the reinforcing sleeve 13. The flexible ribs 19 are all set in an inclined shape. The multiple flexible ribs 19 are respectively located on both sides of the inner wall of the protective sleeve 14.

[0037] The protective sleeve 14 and the sealing sleeve 15 constitute a detachable protective shell. The reinforcing rib 18 and the flexible rib 19 constitute an adaptive support structure to resist external compression and impact. The first mounting strip 16 and the second mounting strip 17 made of Velcro material can realize the quick opening and closing and repeated installation of the protective mechanism. The spiral heat shrink tape 20 is used to seal and lock the joint between the sealing sleeve 15 and the outer protective sleeve 12.

[0038] A method for preparing a composite cable includes the following steps:

[0039] S1: The inner sheath 1 and the internal connecting core 3 provide an independent power transmission channel with reliable insulation; the first filling layer 4 and the second filling layer 6 form a distributed shielding network while filling the structural gaps, effectively suppressing electromagnetic interference between the power and signal cores; when each aluminum-plastic composite tape is wrapped, its metal surface (aluminum layer) ensures its longitudinal electrical continuity through overlapping; after the cable is cabled, these aluminum-plastic composite tape shielding layers are reliably connected to the cable's main ground at the cable end through metal shielding leads or conductive connectors; finally, the insulation layer 7 is used to circumferentially cover the control core 5 to achieve reliable electrical isolation between high and low voltage units;

[0040] S2: A reinforcing shielding layer 8 is provided at intervals outside the insulation layer 7, and then a buffer sleeve 9 is extruded and covered. During extrusion, the molten buffer material flows through the protruding reinforcing shielding layer 8 and is squeezed and guided by it. After cooling, a matching stabilizing groove 10 is formed in situ on the inner wall of the buffer sleeve 9, realizing the mechanical interlocking and stable fixation of the shielding layer. This structure, together with the externally covered reinforcing sleeve 13, constitutes the rigid reinforcing section of the cable.

[0041] S3: Install a protective mechanism on the vulnerable section of the cable: Position the protective sleeve 14 and the sealing sleeves 15 at both ends to the reinforcing sleeve 13 of the outer sheath 12, and quickly lock them together with the first mounting strip 16 and the second mounting strip 17 using Velcro, so that the internal reinforcing ribs 18 and the flexible ribs 19 form a three-dimensional protective net. Finally, wrap the spiral heat shrink tape 20 around the joint between the sealing sleeve 15 and the outer sheath 12 and heat shrink it to achieve a permanent seal at the port.

[0042] Working principle: The connecting core 3 is independently insulated by the connecting sleeve 2, forming a pure power transmission channel. The first filling layer 4 and the second filling layer 6 reduce the coupling interference between the connecting core 3 and the control core 5. The outer insulation layer 7 provides the main insulation, ensuring absolute electrical safety between the high and low voltage units.

[0043] The reinforced shielding layer 8, serving as an electromagnetic shield, is specifically positioned in vulnerable sections of the cable to enhance local shielding effectiveness. Its outer buffer sleeve 9, formed through an extrusion process, creates an interlocking structure, providing buffering and securing the shielding layer. The outermost reinforcing sleeve 13 is tightly integrated with the lower outer sheath 12, reducing direct frictional contact between the outer sheath 12 and the clamp, and providing clear installation guidance. Installers can directly install the clamp onto the reinforcing sleeve 13, utilizing its reinforced structure to withstand the tightening force and preventing the ordinary sheath from being cut or worn. When the clamp is locked, the tightening force is transmitted through the reinforcing sleeve 13 to the entire reinforced section structure below. The reinforcing sleeve 13 converts the pressure into a distributed load, which is further buffered and dispersed by the buffer block 11 and the interlocking buffer sleeve 9, preventing stress from acting directly on the cable core.

[0044] The protective mechanism can be activated as needed. For areas prone to wear, the protective mechanism can be fitted over the reinforcing sleeve 13. The first mounting strip 16 and the second mounting strip 17 enable quick locking, allowing the protective sleeve 14 to tightly wrap around the reinforcing sleeve 13. The internal reinforcing ribs 18 and flexible ribs 19 support the reinforcing sleeve 13 and the outer sheath 12. When subjected to external compression or impact, the reinforcing sleeve 13 and the outer sheath 12 can be supported. The flexible ribs 19 adapt to the bending of the cable, preventing damage caused by excessive bending.

[0045] After the protective sleeve 14 is installed, the reinforcing rib 18 provides rigid support in the radial direction to resist external compression. The flexible rib 19 can adapt to deformation when the cable is bent, avoiding shear force between the protective sleeve 14 and the outer sheath 12. At the same time, in conjunction with the sealing sleeve 15 and the spiral heat shrink tape 20, it prevents moisture and dust from entering the inside of the cable.

[0046] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention.

Claims

1. A composite cable comprising an inner sheath, characterised in that: The inner sheath is internally provided with a connecting sleeve, the connecting sleeve is internally provided with a connecting wire core, the inner sheath is externally provided with a first filling layer at the outer wall of the plurality of connecting sleeves, the outer wall of the inner sheath is circumferentially provided with a control wire core, the outer wall of the inner sheath is provided with an insulating layer, the plurality of control wire cores are located in the insulating layer, the gap between the control wire core and the insulating layer is filled with a second filling layer, the second filling layer is connected to the outer wall of the inner sheath, the middle part of the outer wall of the insulating layer is provided with a reinforcing shielding layer, the outer wall of the insulating layer is provided with a buffer sleeve, the inner wall of the buffer sleeve is provided with a stabilizing groove corresponding to the reinforcing shielding layer, the reinforcing shielding layer is located in the stabilizing groove, and the shape of the stabilizing groove is matched with the shape of the reinforcing shielding layer; The outer wall of the buffer sleeve is circumferentially provided with a buffer block, the outer wall of the plurality of buffer blocks is provided with an outer sheath, the outer wall of the outer sheath is provided with an enhanced sleeve corresponding to the outer wall of the reinforcing shielding layer, the reinforcing shielding layer and the enhanced sleeve are intermittently arranged between the specific vulnerable sections of the cable outer sheath, the enhanced sleeve is used as a special installation base of the wire clamp, the high-strength structure directly bears the fastening force, and the extrusion and wear of the outer sheath by the edge of the wire clamp in the traditional installation are eliminated, and the outer wall of the outer sheath is provided with a protection mechanism corresponding to the outer wall of the enhanced sleeve. The protection mechanism comprises a protection sleeve, the both ends of the protection sleeve are provided with sealing sleeves, the inner walls of the two sealing sleeves are in contact with the outer wall of the outer sheath, the inner walls of the protection sleeves are circumferentially provided with reinforcing ribs, the both ends of the plurality of reinforcing ribs are provided with flexible ribbons, the outer walls of the two sealing sleeves are wound with spiral heat-shrinkable tapes, and the reinforcing ribs and the flexible ribbons in the protection mechanism support the enhanced sleeve and the outer sheath, when the outside is extruded or impacted, the flexible ribbons are adaptively deformed when the cable is bent, and damage caused by excessive bending of the cable is avoided.

2. A composite cable according to claim 1, characterized in that: The connecting sleeve is made of polyvinyl chloride material structure, the connecting wire core is twisted by a plurality of wires, and the first filling layer and the second filling layer are both made of aluminum-plastic composite belt material structure.

3. A composite cable according to claim 2, characterized in that: The buffer sleeve is made of composite material structure, the inner layer of the buffer sleeve is made of silicone rubber material, and the outer layer of the buffer sleeve is made of high-wear-resistant insulating material.

4. A composite cable according to claim 3, characterized in that: The protection sleeve is sleeved on the outer wall of the enhanced sleeve, and the both ends of the protection sleeve are obliquely arranged.

5. A composite cable according to claim 4, characterized in that: The shape of the inner wall of the protection sleeve is matched with the shape of the outer wall of the enhanced sleeve, the protection sleeve and the sealing sleeve are annularly arranged, and the number of the sealing sleeves is two.

6. A composite cable according to claim 5, characterized in that: The first installation strip is arranged on one end of the protection sleeve and one end of the two sealing sleeves, and the second installation strip is arranged on the other end of the protection sleeve and the other end of the two sealing sleeves.

7. A composite cable according to claim 6, characterized in that: The first installation strip and the second installation strip are made of magic tape material, and the first installation strip is adhered to the upper side of the second installation strip.

8. A composite cable according to claim 7, characterized in that: The plurality of reinforcing ribs and the plurality of flexible ribbons are located around the outer wall of the enhanced sleeve, the flexible ribbons are obliquely arranged, and the plurality of flexible ribbons are connected to the inner walls of the protection sleeve on both sides.

9. A method of manufacturing a composite cable based on the composite cable according to claim 8, characterized in that, The following use steps are included: S1: Inner sheath and internal connecting line core, providing independent power transmission channel, reliable insulation; The first filling layer and the second filling layer constitute a distributed shielding network while filling the structure gap, effectively suppressing electromagnetic interference between power and signal line cores. When winding the aluminum-plastic composite belt, the metal surface is ensured to be longitudinally electrically continuous through overlapping lapping. After the cable is formed, the aluminum-plastic composite belt shielding layer at the end of the cable is connected with the total ground of the cable through a metal shielding lead-out wire or a conductive connecting piece. Finally, the control line core is circumferentially covered with an insulating layer to achieve reliable electrical isolation between high and low voltage units. S2: Strengthening shielding layer is arranged outside the insulating layer at intervals, and then a buffer sleeve is extruded. During extrusion, the molten buffer material flows through the protruding strengthening shielding layer and is extruded by it. After cooling, a stable groove matching the buffer sleeve is formed in situ on the inner wall of the buffer sleeve, realizing mechanical interlocking and stable fixation of the shielding layer. This structure cooperates with the external reinforcing sleeve to form a rigid reinforcing section of the cable. S3: Protective mechanism is installed in the vulnerable section of the cable: the protective sleeve and the two end sealing sleeves are positioned at the reinforcing sleeve of the outer sheath, and the internal reinforcing ribs and flexible ribs form a three-dimensional protective net through the quick locking of the first and second installation strips of the magic tape. Finally, the spiral heat shrinkable belt is wound and heat shrunk at the joint of the sealing sleeve and the outer sheath, realizing permanent sealing of the port.

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