Low-temperature-resistant high-voltage flexible cable and processing equipment thereof

Abstract

The invention discloses a low-temperature-resistant high-voltage flexible cable and processing equipment thereof, and belongs to the technical field of cables. Comprising three conductor cores, the conductor cores are wrapped by conductor shielding layers, the outer sides of the three conductor cores are clamped with limiting frames, and connecting ribs are arranged among the three limiting frames to form triangular connection; the three conductor cores are wrapped by a filling layer to form a cable, and a composite shielding layer is braided on the outer side of the cable and comprises a braided layer and a conductive adhesive. A supporting core is also inserted in the middle position among the three conductor cores, and the supporting core passes through the middle part of the connecting rib. A through hole allowing the supporting core to penetrate through is formed in the middle of the connecting rib. The outer side of the composite shielding layer is also provided with a wrapping tape. The low-temperature-resistant and high-voltage-resistant flexible cable and the processing equipment thereof have the beneficial effects that through deep adaptation and cooperation of the cable and the equipment, full-chain optimization from design to manufacturing is realized, and the overall use effect is good.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and more specifically, to a low-temperature resistant high-voltage flexible cable and its processing equipment. Background Technology

[0002] In fields such as energy, rail transportation, polar scientific research, and special equipment, high-voltage flexible cables capable of stable operation in extreme low-temperature environments are frequently required. Existing low-temperature resistant high-voltage flexible cables typically consist of a conductor, conductor shielding layer, insulation layer, insulation shielding layer, metallic shielding layer, filler layer, wrapping layer, and outer sheath.

[0003] However, this type of structure has some shortcomings in practical use. First, in terms of cable structure, traditional three-core cables often use simple soft materials to fill the gaps between the cores. This type of filling structure is prone to hardening at low temperatures and cannot effectively position and support the cores. As a result, under frequent bending or torsional loads, the internal cores are prone to relative displacement, compression, or even torsion, which aggravates insulation wear and affects the long-term electrical reliability and mechanical life of the cable. Second, its metal shielding layer often uses pure copper wire braiding or wrapping structures. In extreme low-temperature environments, the ductility of the metal material decreases, and the shielding layer is prone to breakage during dynamic bending due to embrittlement, leading to a sharp drop in shielding effectiveness. At the same time, the traditional shielding layer and the inner insulating shielding layer are mostly in physical contact, which has problems such as uneven contact resistance and easy generation of micro-discharge.

[0004] Therefore, the present invention provides a low-temperature resistant high-voltage flexible cable and its processing equipment to solve the above-mentioned technical problems. Summary of the Invention

[0005] The summary section of this invention provides a brief overview of the concepts, which will be described in detail in the detailed description section that follows. This summary section is not intended to identify key or essential features of the claimed invention, nor is it intended to limit the scope of the claimed invention.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: A low-temperature resistant high-voltage flexible cable includes three conductor cores, each conductor core is wrapped with a conductor shielding layer, and each of the three conductor cores is snapped with a limiting frame on its outer side. A connecting rib is provided between the three limiting frames to form a triangular connection. The three conductor cores are surrounded by a filler layer to form a cable. The outer side of the cable is woven with a composite shielding layer, which includes a braided layer and conductive adhesive.

[0007] Furthermore, a support core is interspersed at the middle position between the three conductor cores, and the support core passes through the middle of the connecting rib.

[0008] Furthermore, a through hole is provided in the middle of the connecting rib for the support core to pass through.

[0009] Furthermore, a wrapping tape is also provided on the outer side of the composite shielding layer.

[0010] A processing equipment for low-temperature resistant high-voltage flexible cable, applicable to the aforementioned low-temperature resistant high-voltage flexible cable, includes a base, a rotating disk rotatably mounted on the upper end face of the base, a cable guide drum fixed in the middle of the rotating disk for the cable to pass vertically through, and a plurality of spindles arranged around the edge of the rotating disk, with an elastic conductor mechanism provided on one side of each spindle. A fixing frame is mounted above the base, and a braided tube is mounted on the fixing frame at the position directly above the wire guide tube. A coating mechanism for spraying conductive adhesive is provided in the middle of the braided tube. The fixed frame is also equipped with a take-up reel, and the braiding drum is located between the take-up position of the take-up reel and the top position of the guide drum.

[0011] Furthermore, the coating mechanism includes a processing ring arranged around the center of the braided cylinder, a plurality of nozzles facing the center of the braided cylinder are arranged on the inner side of the processing ring, and a filler layer is connected to the processing ring.

[0012] Furthermore, the elastic conductor mechanism includes a support frame vertically fixed to one side of the bottom of the spindle, a vertical limiting groove is provided at the top of the support frame, a slider is elastically installed in the limiting groove, and a guide hole is provided in the middle of the slider.

[0013] Furthermore, a movable shaft is fixed to the bottom of the slider, the lower end of the movable shaft is vertically inserted into the bottom of the limiting groove, and an elastic element is sleeved on the movable shaft.

[0014] Furthermore, one end of the elastic element is connected to the bottom of the limiting groove, and the other end is connected to the bottom of the slider.

[0015] Furthermore, a guide roller is rotatably mounted on the outer top of the support frame.

[0016] The beneficial effects of this invention are as follows: In the above scheme, by setting a triangular rigid skeleton consisting of a limiting frame and an optional support core in the middle on the outside of the core, the relative position of the three conductor cores can be effectively constrained and the axial compressive strength of the cable core can be enhanced. This fundamentally improves the structural stability of the cable from the inside and prevents the insulation layer from being worn due to core displacement. In the above scheme, by setting a shielding layer composed of a braided metal layer and conductive adhesive in situ on the outside of the cable, the conductive adhesive can fill the gaps, bond and conduct electricity, which helps to maintain the continuous flexibility of the shielding layer, eliminate partial discharge and greatly improve electromagnetic compatibility at extreme low temperatures. In the above solution, by cooperating with the rotating spindle unit in the processing equipment and the braided cylinder with an integrated ring spraying mechanism located on the same axis above it, the precision braiding of the metal wire and the quantitative spraying of the conductive adhesive can be completed simultaneously during the vertical passage of the cable core. This integrates the traditional multi-stage dispersed process into a one-step continuous forming, high-efficiency and high-quality production process for composite shielding layers, greatly improving processing efficiency. In the above scheme, by setting up a slider guide hole mechanism supported by elastic elements and capable of vertical floating in each spindle unit, the tension of each braided thread can be adaptively and finely adjusted in real time, ensuring dynamic uniformity of tension during the braiding process, thereby ensuring that the composite shielding layer structure is tight and has low-temperature flexibility. In the above solution, by matching the specific structure of the cable with the process flow of the special equipment, the stable cable core supported by the internal limiting frame can provide an ideal processing substrate for the external synchronous braiding and spraying, so that the equipment can perfectly realize the innovative cable structure and the two work together to ensure the optimal performance of the final product. In summary, the low-temperature resistant high-voltage flexible cable and its dedicated processing equipment provided in this solution not only represent significant advancements in structural innovation and process integration, but also achieve full-chain optimization from design to manufacturing through deep adaptation and synergy between the cable and the equipment, resulting in excellent overall performance. Attached Figure Description

[0017] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention, making other features, objects, and advantages of the invention more apparent. The illustrative embodiments of the invention illustrated in the drawings and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention.

[0018] Furthermore, throughout the accompanying drawings, the same or similar reference numerals denote the same or similar elements. It should be understood that the drawings are schematic, and the elements are not necessarily drawn to scale.

[0019] In the attached diagram: Figure 1 This is a schematic diagram of the low-temperature resistant high-voltage flexible cable of the present invention; Figure 2 This is a schematic diagram of the supporting core of the low-temperature resistant high-voltage flexible cable of the present invention; Figure 3 This is a schematic diagram of the limiting frame of the low-temperature resistant high-voltage flexible cable of the present invention. Figure 4This is a schematic diagram of the processing equipment of the present invention; Figure 5 This is a schematic diagram of the structure of the spindle in the processing equipment of the present invention; Figure 6 This is a schematic diagram of the structure of the braided drum of the processing equipment of the present invention.

[0020] Figure label: 1. Conductor core; 2. Conductor shielding layer; 3. Insulating shielding layer; 4. Support core; 5. Limiting frame; 501. Connecting rib; 502. Through hole; 6. Filling layer; 7. Composite shielding layer; 701. Wrapping tape; 8. Base; 9. Rotating disk; 10. Spindle; 1001. Support frame; 1002. Limiting groove; 1003. Slider; 1004. Guide hole; 1005. Guide roller; 1006. Movable shaft; 1007. Elastic element; 11. Wire guide drum; 1101. Receiving hopper; 1002. Discharge pipe; 12. Fixing frame; 13. Take-up reel; 14. Braiding drum; 15. Processing ring; 16. Conveying pipe. Detailed Implementation

[0021] The following is a detailed description of a low-temperature resistant high-voltage flexible cable and its processing equipment provided by the present invention, with reference to the accompanying drawings and specific embodiments. It should be noted that, to make the embodiments more detailed, the following embodiments are the best and preferred embodiments; those skilled in the art can also use other alternative methods to implement some known technologies; and the accompanying drawings are only for more specific description of the embodiments and are not intended to specifically limit the present invention.

[0022] It should be noted that the use of terms such as "an embodiment," "an embodiment," "an exemplary embodiment," and "some embodiments" in the specification indicates that the described embodiment may include a specific feature, structure, or characteristic, but not every embodiment necessarily includes that specific feature, structure, or characteristic. Furthermore, when a specific feature, structure, or characteristic is described in connection with an embodiment, implementing such a feature, structure, or characteristic in conjunction with other embodiments (whether explicitly described or not) should be within the knowledge of those skilled in the art.

[0023] Generally, terms can be understood at least partly from their use in context. For example, depending at least partly on the context, the term "one or more" as used herein can be used to describe any feature, structure, or characteristic in a singular sense, or a combination of features, structures, or characteristics in a plural sense. Additionally, the term "based on" can be understood not necessarily to convey an exclusive set of factors, but rather, alternatively, depending at least partly on the context, to allow for the presence of other factors that are not necessarily explicitly described.

[0024] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0025] Reference Figure 1-3 As shown, the present invention provides a low-temperature resistant high-voltage flexible cable, the core structure of which includes three conductor cores 1 extending along the length of the cable. Each conductor core 1 is composed of an inner metal conductor, a conductor shielding layer 2 directly covering the conductor, an insulation layer (including XLPE or EPR material) covering the conductor shielding layer 2, and an outermost insulating shielding layer 3.

[0026] To fundamentally solve the problem of unstable internal structure in three-core cables, an arc-shaped limiting frame 5 is fixed to the outside of the insulation shielding layer 3 of each conductor core 1 by means of snap-fit, bonding, or in-mold molding. This limiting frame 5 can be made of low-temperature resistant engineering plastic. The three limiting frames 5 are evenly distributed in the circumferential direction, and every two adjacent limiting frames 5 are connected to each other at the ends by a connecting rib 501, thus forming a stable triangular frame structure surrounding the cable axis. To further enhance the longitudinal stiffness and compressive strength of this frame, a support core 4 can be inserted axially at the center of the cable where the three connecting ribs 501 intersect. For this purpose, a through hole 502 is opened at the intersection of the connecting ribs 501, through which the support core 4 (in specific implementations, it can be, but is not limited to, aramid fiber bundles) passes. The cable core unit, composed of three conductor cores 1 with limiting frames 5 and optional support cores 4, is externally covered by a filling layer 6. The filler layer 6 can be made of elastic materials such as silicone rubber or cold-resistant TPU, and can be formed by extrusion or casting to integrate the aforementioned cable core units into a cable body with a round cross-section.

[0027] A composite shielding layer 7 is provided on the outer side of the cabling body. This layer is processed by specialized equipment and has the following structure: First, a metal braided mesh made of tin-plated copper wire or copper alloy wire is woven. Simultaneously, a special low-temperature resistant conductive adhesive is applied and uniformly to fill the mesh of the braided mesh and firmly bonded between the braided mesh and the surface of the inner cabling body filling layer 6. After curing, this conductive adhesive not only provides adhesion but also establishes a continuous conductive path. To temporarily fix and protect the composite shielding layer 7, one or more layers of wrapping tape 701 are usually wrapped around its outer side. Depending on the requirements of the final use environment, an inner sheath, an armor layer, and an outer sheath (not shown in the figure) can be sequentially provided outside the wrapping tape 701.

[0028] In practical implementation, to ensure the reliable function of the composite shielding layer 7 in extremely low temperature environments, the aforementioned conductive adhesive is a specially formulated composite material whose design must simultaneously meet the requirements of conductivity, adhesion, low-temperature elasticity, and sprayability. Specifically, it includes a matrix resin (approximately 40% to 60% of the total adhesive mass), conductive fillers (flaky silver powder or silver-plated copper powder, accounting for approximately 30% to 50% of the total adhesive mass, and may contain approximately 1% to 5% carbon nanotubes or graphene), and an additive system (containing low-temperature toughening agents such as long-chain alkane plasticizers or liquid silicone oil, adhesion promoters such as silane coupling agents, and thixotropic agents such as fumed silica).

[0029] like Figures 4-6 As shown, to efficiently and with high quality manufacture the aforementioned cable with composite shielding layer 7, the present invention also provides a corresponding dedicated processing equipment. This equipment includes a horizontally fixed base 8. A rotating disk 9, rotatable about a vertical axis, is rotatably mounted in the center of the base 8 via a large slewing bearing. A vertical guide drum 11 is fixedly mounted at the center of the rotating disk 9, through which the cable to be processed passes vertically upward. A receiving hopper 1101 is provided at the top of the guide drum 11 to collect any dripping material, and a discharge pipe 1102 is provided on the bottom side of the guide drum 11 for slag removal. Multiple spindles 10 are evenly mounted around the circumference of the guide drum 11 on the rotating disk 9, each spindle 10 carrying a spool of metal wire for braiding.

[0030] Each spindle 10 is equipped with an elastic wire guide mechanism on its side. This mechanism includes a support frame 1001 vertically fixed to a rotating disk 9. A vertically oriented strip-shaped limiting groove 1002 is formed at the top of the support frame 1001. A slider 1003 is inserted downwards into the limiting groove 1002 via a movable shaft 1006 fixed at its bottom. An elastic element 1007 is fitted onto the movable shaft 1006; the upper end of the elastic element 1007 abuts against the bottom of the slider 1003, and the lower end abuts against the bottom of the limiting groove 1002 or a fixed part connected thereto, thereby giving the slider 1003 vertical elastic floating capability. A guide hole 1004 is formed at the center of the slider 1003, through which the metal wire passes. A guide roller 1005 is also installed on the outer top of the support frame 1001 to change the direction of the metal wire and reduce friction. The metal wire unwound from spindle 10 first passes through guide roller 1005, then through guide hole 1004, and finally converges towards the center of the equipment.

[0031] Above the base 8, a gate-shaped mounting bracket 12 is fixed. A take-up reel 13 for pulling and winding the finished cable is mounted on the mounting bracket 12. On the mounting bracket 12, directly opposite the centerline of the lower cable reel 11, a braided drum 14 is fixedly mounted. The center hole of the braided drum 14 allows the cable core to pass through vertically. A processing ring 15 is constructed around the center of the braided drum 14. The processing ring 15 is connected to an external adhesive supply system (such as a pressure tank or metering pump) via a delivery pipe 16. On the inner ring wall of the processing ring 15, multiple micro-nozzles (not shown in the figure) are evenly distributed along the circumference, all facing the central axis of the braided drum 14.

[0032] The working process of the equipment is as follows: the cable body, which has completed the aforementioned core unit and filling layer 6, is pulled from below the equipment, passes vertically through the guide drum 11 at the center of the rotating disk 9, continues upward through the center hole of the braiding drum 14, and is finally pulled and wound up by the take-up reel 13. After the equipment is started, the rotating disk 9 is driven to rotate by a drive mechanism (such as a motor), thereby causing all the spindles 10 to revolve around the cable body. The metal wires on each spindle 10 are unwound and pass through the elastic conductor mechanism. The slider 1003 in the elastic conductor mechanism can float up and down with the tension change under the action of the elastic element 1007, dynamically adjusting the output tension and keeping it constant.

[0033] The metal wires begin to interweave at a convergence point below the braiding drum 14, forming a braided mesh on the surface of the cable. Simultaneously, the adhesive supply system activates, delivering conductive adhesive through the delivery pipe 16 to the processing ring 15, which is then sprayed simultaneously from multiple nozzles on its inner wall, forming a uniform mist or stream of adhesive that surrounds the cable, precisely coating the interface area between the forming braided mesh and the cable surface. Braiding and spraying occur concurrently; the conductive adhesive is carried by the braided wires and filled into all the mesh gaps, achieving in-situ bonding. Subsequently, the cable with the composite shielding layer 7 is wound up by the take-up reel 13, completing the online continuous manufacturing of the composite shielding layer. This equipment achieves integrated, continuous operation from cabling to composite shielding layer formation, ensuring product structural consistency and high performance.

[0034] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

[0035] It should be noted that this invention encompasses any substitutions, modifications, equivalent methods, and solutions made within the spirit and scope of this invention. To provide the public with a thorough understanding of this invention, specific details are described in detail in the preferred embodiments; however, those skilled in the art will fully understand the invention even without these details. Furthermore, to avoid unnecessary confusion regarding the essence of this invention, well-known methods, processes, procedures, components, and circuits are not described in detail.

[0036] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A low-temperature resistant high-voltage flexible cable, comprising three conductor cores (1), wherein the conductor cores (1) are externally wrapped with a conductor shielding layer (2), characterized in that: The outer sides of the three conductor cores (1) are all snapped with limit frames (5), and the three limit frames (5) are provided with connecting ribs (501) to form a triangular connection; The three conductor cores (1) are surrounded by a filling layer (6) to form a cable. The outer side of the cable is woven with a composite shielding layer (7), which includes a braided layer and conductive adhesive.

2. The low-temperature resistant high-voltage flexible cable according to claim 1, characterized in that: A support core (4) is also inserted at the middle position between the three conductor cores (1), and the support core (4) passes through the middle of the connecting rib (501).

3. The low-temperature resistant high-voltage flexible cable according to claim 2, characterized in that: The connecting rib (501) has a through hole (502) in the middle for the support core (4) to pass through.

4. The low-temperature resistant high-voltage flexible cable according to claim 1, characterized in that: The outer side of the composite shielding layer (7) is also provided with a wrapping tape (701).

5. A processing equipment for low-temperature resistant high-voltage flexible cables, applicable to the low-temperature resistant high-voltage flexible cable described in any one of claims 1-4, characterized in that: Includes a base (8), on which a rotating disk (9) is rotatably mounted on the upper surface of the base (8), and a wire guide (11) for the cable to pass vertically is fixed in the middle of the rotating disk (9), and several spindles (10) are arranged around the edge of the rotating disk (9), and an elastic wire mechanism is provided on one side of the spindle (10). A fixing frame (12) is mounted above the base (8). A braided tube (14) is mounted on the fixing frame (12) at the position directly above the wire guide tube (11). A coating mechanism for spraying conductive adhesive is provided in the middle of the braided tube (14). The fixed frame (12) is also equipped with a take-up reel (13), and the braiding drum (14) is located between the take-up position of the take-up reel (13) and the top position of the guide drum (11).

6. The processing equipment for low-temperature resistant high-voltage flexible cables according to claim 5, characterized in that: The coating mechanism includes a processing ring (15) arranged around the middle of the braided cylinder (14), and a plurality of nozzles facing the center of the braided cylinder (14) are arranged on the inner side of the processing ring (15), and a filling layer (6) is connected to the processing ring (15).

7. The processing equipment for low-temperature resistant high-voltage flexible cables according to claim 5, characterized in that: The elastic conductor mechanism includes a support frame (1001) vertically fixed to one side of the bottom of the spindle (10). The top of the support frame (1001) is provided with a vertically oriented limiting groove discharge pipe (1002). A slider (1003) is elastically installed inside the limiting groove discharge pipe (1002). A guide hole (1004) is provided in the middle of the slider (1003).

8. The processing equipment for low-temperature resistant high-voltage flexible cables according to claim 7, characterized in that: The bottom of the slider (1003) is fixed with a movable shaft (1006), the lower end of the movable shaft (1006) is vertically inserted into the bottom of the limiting groove discharge pipe (1002), and an elastic element (1007) is sleeved on the movable shaft (1006).

9. The processing equipment for low-temperature resistant high-voltage flexible cables according to claim 8, characterized in that: One end of the elastic element (1007) is connected to the bottom of the limiting groove discharge pipe (1002), and the other end is connected to the bottom of the slider (1003).

10. The processing equipment for low-temperature resistant high-voltage flexible cables according to claim 5, characterized in that: A guide roller (1005) is rotatably mounted on the outer top of the support frame (1001).

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