A wear-resistant insulating strain clamp and a preparation method thereof

Abstract

The application discloses a wear-resistant and insulating strain clamp and a preparation method thereof, and belongs to the technical field of cable or wire installation. The clamp comprises an integrated insulating shell, a layered clamping lining and an elastic locking mechanism. The layered clamping lining comprises a wear-resistant layer, an elastic buffer layer and an insulating layer from inside to outside. The inner surface of the wear-resistant layer is provided with friction texture or roughening structure to increase friction and prevent slippage. The elastic locking mechanism is composed of a spring, a locking mandrel and a locking block. The clamping surface of the locking block is an arc surface or a V-shaped surface and is provided with a tooth structure. Under the action of spring pre-tightening and external tension, the locking block forms self-locking clamping that becomes tighter with tension. A limiting seat limits the stroke of the locking block, and a positioning ring realizes axial positioning and limiting. Compared with the prior art, the wear-resistant and insulating strain clamp has the advantages of insulation protection, wear resistance, vibration reduction, high gripping force and anti-slip, and high assembly reliability.

Description

Technical Field

[0001] This invention relates to the field of cable or wire installation technology, and in particular to a wear-resistant, insulating, and tension-resistant wire clamp and its preparation method. Background Technology

[0002] In existing power transmission and distribution lines and various cable installation scenarios, tension clamps are used to fix, bear force, and prevent slippage of cables, and are key connecting components to ensure stable line tension and safe operation. As lines are subjected to complex conditions such as wind vibration, icing, temperature changes, and mechanical tension for extended periods, the contact interface between the clamp and the cable is prone to wear, localized stress concentration, and weakening of gripping force. At the same time, some application scenarios place higher demands on insulation protection, requiring clamps to meet tension gripping requirements while also ensuring electrical insulation, wear resistance, and reliable locking, and minimizing installation and maintenance difficulty.

[0003] For example, the tension clamp disclosed in CN 111614045A focuses on improving self-sealing and corrosion resistance through self-sealing components and galvanizing processes. However, its main focus is on locking and corrosion resistance, making it difficult to simultaneously address the integrated needs of wear resistance, buffering, and insulation at the cable contact surface. The assembled tension clamp protection device disclosed in CN 119602150A reduces line sway wear through additional protection and buffering structures. However, it is an external protection device solution with a relatively complex structure and does not achieve integrated improvement of wear resistance, friction enhancement, and self-locking clamping at the clamp body's gripping interface. The tension clamp for cable erection disclosed in CN 113300303A improves gripping force through tensioning components, pre-twisted wires, and fastening structures. However, it has many structural components, complex assembly and adjustment processes, and insufficient consideration for the coordinated design of insulation protection and wear resistance buffering.

[0004] Therefore, existing technologies generally suffer from the following problems: First, the clamping interface lacks a composite structure that combines wear resistance, friction enhancement, and cushioning, leading to wear and tear over long-term operation, resulting in decreased gripping force and increased risk of slippage. Second, the locking mechanism is prone to clamping force fluctuations, skewness, jamming, or insufficient stability under stress and vibration conditions, affecting reliability. Third, some solutions fail to achieve the synergistic integration of insulation protection and tension resistance / anti-slip properties of the clamp body, making it difficult to simultaneously meet the requirements of convenient installation, long-term durability, and safe insulation. Therefore, there is an urgent need for a self-locking clamping mechanism that can achieve stable guiding and limiting within an insulating shell, combined with a wear-resistant, friction-enhancing, and elastically cushioning layered lining structure, along with its manufacturing method, to improve anti-slip capability, reduce wear, and enhance long-term operational reliability. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention aims to provide a wear-resistant, insulating, and tension-resistant wire clamp and its preparation method.

[0006] To achieve the above-mentioned objectives, the present invention adopts the following technical solution:

[0007] A method for preparing a wear-resistant, insulating, and tension clamp is as follows, comprising the following steps:

[0008] S1. Preparation of an integrated insulating shell: An insulating polymer material is used to make a shell blank by injection molding or compression molding, and an inner cavity for accommodating a layered clamping liner and a locking mechanism cavity for accommodating a spring, a locking mandrel and a locking block are formed in the shell blank.

[0009] S2. Preparation of layered clamping liner: The wear-resistant liner layer, the elastic buffer liner layer and the insulating liner layer are formed separately, and the wear-resistant liner layer, the elastic buffer liner layer and the insulating liner layer are sequentially combined from the inside to the outside to form a sleeve-shaped layered clamping liner.

[0010] S3. Insert the layered clamping liner into the integrated insulating shell, so that the layered clamping liner and the integrated insulating shell form a through cable channel.

[0011] S4. Assemble the elastic locking mechanism: Install the spring and the end of the locking spindle, and connect the locking block and the locking spindle.

[0012] S5. The elastic locking mechanism assembled in step S4 is installed into the locking mechanism cavity and positioned in conjunction with the limiting seat, so that the locking block is clamped and displaced toward the cable channel under the action of the spring force.

[0013] S6. Assemble the left end sleeve and the right end sleeve at both ends of the integrated insulating shell, and assemble the positioning ring between the right end sleeve and the limiting seat to axially position and limit the elastic locking mechanism; thus completing the wear-resistant insulating tension clamp.

[0014] In step S2, the inner surface of the wear-resistant lining layer corresponding to the cable channel is formed with friction texture or roughened structure to increase friction and improve the anti-slip capability between the inner surface and the cable.

[0015] The inner elastic buffer layer described in step S2 gives it compressible resilience in the radial direction to absorb the force, vibration and impact of the cable, and achieve adaptive fitting for cables with different outer diameters.

[0016] In step S2, the inner insulating layer and the integrated insulating shell are fitted together or bonded together to ensure electrical insulation and structural support between the cable and the shell.

[0017] The composite method of the layered clamping liner mentioned in step S2 is any one of co-extrusion composite molding, secondary coating molding or lamination bonding, and after composite, a coaxial sleeve structure is formed and coaxial with the cable channel.

[0018] In step S4, the locking block has a V-shaped serrated surface formed on its working surface opposite to the cable channel during molding or post-processing, so that the locking block produces a friction-increasing self-locking effect on the cable when subjected to external tension.

[0019] In step S5, the travel of the locking block is limited by the limiting seat so that the locking block maintains a stable clamping direction under the action of the spring and avoids deflection and jamming.

[0020] In step S2, the material of the inner wear-resistant lining layer is any one of thermoplastic polyurethane, polyurethane rubber, or nylon; the material of the inner elastic buffer lining layer is any one of silicone rubber, ethylene propylene rubber, or nitrile rubber; and the material of the inner insulating lining layer is any one of cross-linked polyethylene, polyethylene, polypropylene, or epoxy resin.

[0021] In steps S4 to S5, the spring, locking spindle, and locking block are assembled to form an elastic locking mechanism; the locking block has a clamping surface that is opposite to the cable channel and is connected to the locking spindle, and the clamping surface is a V-shaped serrated surface;

[0022] The locking block also has a guide surface or guide groove that cooperates with the limiting seat, so that the locking block moves in a predetermined direction towards the cable channel under the guidance of the limiting seat to achieve clamping and locking.

[0023] The integrated insulating housing provides insulation protection and structural support for the entire device. Internally, it forms a cavity for installing a layered clamping liner and a locking mechanism cavity for installing a resilient locking mechanism. The housing and the layered clamping liner together define a through-path for the cable, ensuring that when the cable is inserted and subjected to axial force, the liner and locking mechanism jointly bear the tensile force while maintaining electrical isolation and mechanical stability.

[0024] The layered clamping liner is composed of a wear-resistant inner liner, an elastic buffer inner liner, and an insulating inner liner, arranged from the inside out in a coaxial sleeve structure. The wear-resistant inner liner directly contacts the outer surface of the cable, and its friction texture or roughened structure is used to increase the coefficient of friction, improving anti-slip capability and reducing wear at the contact interface. The elastic buffer inner liner is compressible and resilient in the radial direction, making the clamping contact pressure more uniform, absorbing vibration and impact caused by cable stress, and forming an adaptive fit for cables of different outer diameters, reducing local stress concentration. The insulating inner liner is located between the inner liner and the outer shell, and is fixed to the integrated insulating outer shell through bonding or adhesive assembly. On the one hand, it forms a stable insulating isolation, and on the other hand, it provides a support interface, making the inner liner less prone to displacement or roll-up under clamping load, thereby ensuring the shape stability of the cable channel and reliable clamping.

[0025] A spring, locking spindle, and locking block are assembled to form a resilient locking mechanism. The spring is arranged axially along the locking spindle and provides a continuous preload, causing the locking spindle to exert a pushing force on the locking block. This causes the locking block to clamp and displace towards the cable channel, achieving initial clamping and holding force on the cable. This preload structure ensures that the cable is in a controlled clamped state after installation, preventing loosening and fretting wear.

[0026] The clamping surface of the locking block can be arc-shaped or V-shaped, enabling it to form surface or line contact with the outer surface of the cable and achieve effective clamping. The clamping surface is equipped with teeth, serrations, or a coarsened structure to further increase friction and suppress axial slippage. The force-bearing end face of the locking block is connected to the locking mandrel, converting the axial thrust of the locking mandrel into a radial clamping force on the cable. Under external tension, when the cable tends to slip relative to the cable, the locking block, under friction, more easily forms a self-locking tendency that tightens with increasing tension, thereby improving pull-out resistance and reducing slippage.

[0027] The limiting seat works in conjunction with the elastic locking mechanism to position and limit the stroke of the locking block. Through guidance and limiting, the movement direction of the locking block is constrained to a predetermined direction towards the cable channel, avoiding uneven clamping and damage caused by skewness, jamming, or excessive displacement. At the same time, it ensures that the locking mechanism can maintain a stable clamping posture and repeatable working state under long-term stress and vibration environment.

[0028] The left and right sleeves are respectively installed at both ends of the integrated insulating shell for end sealing, assembly positioning, and providing transition support for cable entry and exit points, thereby improving end stress and assembly stability. A positioning ring is placed between the right sleeve and the limiting seat to axially position and limit the elastic locking mechanism, ensuring that the spring preload, the working stroke of the locking spindle, and the clamping position of the locking block are within the design range, preventing fluctuations in clamping force or loosening of the device due to axial movement.

[0029] In summary, the integrated insulating outer shell and the inner insulating lining together ensure electrical insulation and structural load-bearing capacity. The wear-resistant inner lining and the friction-enhancing surface of the locking block together provide a high-friction, anti-slip interface. The elastic buffer inner lining provides pressure equalization and buffering to reduce stress concentration. The spring and locking mandrel provide continuous preload and drive the locking block to clamp. The limit seat and positioning ring ensure that the movement of the locking mechanism is controlled and the position is stable, thereby achieving a synergistic effect of wear resistance, insulation, and tension resistance to prevent slippage.

[0030] Compared with existing technologies, it has the following advantages:

[0031] 1) The locking block of this invention, in conjunction with the spring preload and friction-enhancing teeth, achieves a self-locking clamping that tightens as it is pulled, thereby improving its anti-slip and anti-pull-out capabilities.

[0032] 2) The wear-resistant layer and elastic buffer layer of the layered clamping liner of this invention work together to equalize pressure and reduce vibration, thereby reducing surface wear and stress concentration of the cable and extending its service life.

[0033] 3) The present invention uses a limiting seat for guiding and limiting, combined with a positioning ring for axial limiting, to avoid misalignment and jamming of the locking parts and fluctuation of clamping force, thereby improving assembly consistency and reliability. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the structure of the present invention.

[0035] Figure 2 This is an enlarged side view of the locking mandrel 6, locking block 7 and limiting seat 8 of the present invention.

[0036] In the diagram: 1. Integrated insulating shell; 2. Left sleeve; 3. Right sleeve; 4. Layered clamping liner; 4a. Wear-resistant liner; 4b. Elastic buffer liner; 4c. Insulating liner; 5. Spring; 6. Locking spindle; 7. Locking block; 8. Limit seat; 9. Cable channel; 10. Positioning ring. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0038] This embodiment provides a wear-resistant, insulating, and tension-resistant cable clamp, which includes an integrated insulating shell 1, a left end sleeve 2, a right end sleeve 3, a layered clamping liner 4, a spring 5, a locking mandrel 6, a locking block 7, a limiting seat 8, a cable channel 9, and a positioning ring 10. The layered clamping liner 4 is disposed in the inner cavity of the integrated insulating shell 1, and the layered clamping liner 4 and the integrated insulating shell 1 together form a through cable channel 9 for cable insertion. The layered clamping liner 4 includes, from the inside out, an inner wear-resistant liner 4a, an inner elastic buffer layer 4b, and an inner insulating layer 4c. The inner wear-resistant liner 4a is in direct contact with the cable, the inner elastic buffer layer 4b is used to buffer the force and achieve a close fit, and the inner insulating layer 4c cooperates with the integrated insulating shell 1 to achieve electrical insulation and structural support.

[0039] A locking mechanism cavity is also provided within the integrated insulating housing 1, and an elastic locking mechanism is installed within the locking mechanism cavity. The elastic locking mechanism is assembled from a spring 5, a locking spindle 6, and a locking block 7. The locking spindle 6 is fitted with the end of the spring 5, and the locking block 7 is connected to the locking spindle 6. A limiting seat 8 is located within the locking mechanism cavity and cooperates with the elastic locking mechanism for positioning. The limiting seat 8 limits the stroke of the locking block 7, thereby maintaining a stable clamping direction and preventing skewness and jamming. Under the elastic force of the spring 5, the locking block 7 generates a clamping displacement towards the cable channel 9, achieving clamping and locking of the cable.

[0040] The locking block 7 has a clamping surface opposite to the cable channel 9 and a locking mandrel 6 that is connected to it. The clamping surface is a V-shaped serrated surface. To improve friction resistance and anti-slip capability, the locking block 7 is also provided with a guide surface that cooperates with the limiting seat 8, so that the locking block 7 moves towards the cable channel 9 in a predetermined direction under the guidance of the limiting seat 8, thereby achieving clamping and locking.

[0041] In this embodiment, the layered clamping liner 4 adopts a composite structure and forms a coaxial sleeve shape, coaxial with the cable channel 9. The layered clamping liner 4 is prepared by co-extrusion composite molding. The wear-resistant layer 4a of the liner is made of nylon material, and friction texture is formed on its inner surface corresponding to the cable channel 9 to increase friction. The elastic buffer layer 4b of the liner is made of ethylene propylene rubber, which gives it compressible resilience in the radial direction to absorb the force, vibration and impact of the cable and achieve adaptive fitting for cables of different outer diameters. The insulating layer 4c of the liner is made of polyethylene material and is connected to the integrated insulating shell 1 by a bonding assembly method to ensure electrical insulation and structural support between the cable and the shell.

[0042] The preparation method of this wear-resistant, insulating, and tension clamp is as follows, including the following steps:

[0043] S1. Preparation of integrated insulating shell 1: The shell blank is made by injection molding or compression molding using insulating polymer material, and an inner cavity for accommodating the layered clamping liner 4 and a locking mechanism cavity for accommodating the spring 5, locking spindle 6 and locking block 7 are integrally formed in the shell blank.

[0044] S2. Preparation of layered clamping liner 4: The wear-resistant liner 4a, the elastic buffer liner 4b, and the insulating liner 4c are formed separately, and the wear-resistant liner 4a, the elastic buffer liner 4b, and the insulating liner 4c are co-extruded and compounded from the inside to the outside to form a sleeve-shaped layered clamping liner 4; wherein the inner surface of the wear-resistant liner 4a forms a friction texture.

[0045] S3. Assemble the layered clamping liner 4: Insert the layered clamping liner 4 into the inner cavity of the integrated insulating shell 1, so that the layered clamping liner 4 and the integrated insulating shell 1 form a through cable channel 9; the inner insulating layer 4c and the integrated insulating shell 1 are fixed by fitting together.

[0046] S4. Assemble the elastic locking mechanism: Install the spring 5 and the end of the locking spindle 6 together, and connect the locking block 7 and the locking spindle 6 together; wherein the locking block 7 has a clamping surface that is opposite to the cable channel 9 and is connected to the locking spindle 6 together, and the clamping surface is a V-shaped sawtooth surface;

[0047] S5. Assemble and position the elastic locking mechanism: Install the elastic locking mechanism assembled in step S4 into the locking mechanism cavity and position it in conjunction with the limiting seat 8. The limiting seat 8 limits the stroke of the locking block 7, so that the locking block 7 will generate a clamping displacement towards the cable channel 9 under the action of the spring force of the spring 5.

[0048] S6. End assembly and limiting: The left end sleeve 2 and the right end sleeve 3 are respectively assembled at both ends of the integrated insulating shell 1, and the positioning ring 10 is assembled between the right end sleeve 3 and the limiting seat 8 for axial positioning and limiting of the elastic locking mechanism, thus completing the wear-resistant, insulating and tension clamp product.

[0049] The above embodiments are merely preferred embodiments of the present invention. Those skilled in the art can make various modifications or substitutions without departing from the concept of the present invention, and all such modifications or substitutions should fall within the protection scope of the present invention.

Claims

1. A method for preparing a wear-resistant, insulating, and tension-resistant wire clamp, characterized in that, Includes the following steps: S1. Preparation of integrated insulating shell (1): The shell blank is prepared by injection molding or compression molding using insulating polymer material, and an inner cavity for accommodating the layered clamping liner (4) and a locking mechanism cavity for accommodating the spring (5), locking mandrel (6) and locking block (7) are formed in the shell blank. S2. Preparation of layered clamping liner (4): The wear-resistant liner (4a), the elastic buffer liner (4b) and the insulating liner (4c) are formed respectively, and the wear-resistant liner (4a), the elastic buffer liner (4b) and the insulating liner (4c) are sequentially combined from the inside to the outside to form a sleeve-shaped layered clamping liner (4). S3. Insert the layered clamping liner (4) into the integrated insulating shell (1) so that the layered clamping liner (4) and the integrated insulating shell (1) form a through cable channel (9). S4. Assemble the elastic locking mechanism: Install the spring (5) and the end of the locking spindle (6) together, and connect the locking block (7) and the locking spindle (6) together; S5. The elastic locking mechanism assembled in step S4 is installed into the locking mechanism cavity and positioned in conjunction with the limiting seat (8) so that the locking block (7) is clamped in the direction of the cable channel (9) under the action of the spring (5). S6. Install the left end sleeve (2) and the right end sleeve (3) at both ends of the integrated insulating shell (1), and install the positioning ring (10) between the right end sleeve (3) and the limiting seat (8) for axial positioning and limiting of the elastic locking mechanism; complete the finished wear-resistant insulating tension clamp.

2. The preparation method according to claim 1, characterized in that: The material of the wear-resistant inner lining layer (4a) in step S2 is any one of thermoplastic polyurethane, polyurethane rubber or nylon; and a friction texture or roughening structure for increasing friction is formed on its inner surface corresponding to the cable channel (9).

3. The preparation method according to claim 1, characterized in that: The material of the inner elastic buffer layer (4b) mentioned in step S2 is any one of silicone rubber, ethylene propylene rubber or nitrile rubber.

4. The preparation method according to claim 1, characterized in that: The material of the inner insulating layer (4c) in step S2 is any one of cross-linked polyethylene, polyethylene, polypropylene or epoxy resin; and the inner insulating layer (4c) and the integrated insulating shell (1) are fitted or bonded together.

5. The preparation method according to claim 1, characterized in that: The composite method of the layered clamping liner (4) in step S2 is any one of co-extrusion composite molding, secondary coating molding or lamination bonding, and after composite, it forms a coaxial sleeve structure and is coaxial with the cable channel (9).

6. The preparation method according to claim 1, characterized in that: In step S4, the locking block (7) forms a V-shaped sawtooth surface on its working surface opposite to the cable channel (9) during molding or post-processing, so that the locking block (7) produces a friction-increasing self-locking effect on the cable when subjected to external tension.

7. The preparation method according to claim 1, characterized in that: In step S5, the travel of the locking block (7) is limited by the limiting seat (8) so that the locking block (7) maintains a stable clamping direction under the action of the spring (5) and avoids deflection and jamming.

8. The preparation method according to claim 1, characterized in that: In steps S4 to S5, the spring (5), locking spindle (6) and locking block (7) are assembled to form an elastic locking mechanism; the locking block (7) has a clamping surface that is opposite to the cable channel (9) and is connected to the locking spindle (6), and the clamping surface is a V-shaped sawtooth surface.

9. The preparation method according to claim 8, characterized in that: The locking block (7) also has a guide surface or guide groove that cooperates with the limiting seat (8), so that the locking block (7) moves in a predetermined direction towards the cable channel (9) under the guidance of the limiting seat (8) to achieve clamping and locking.

10. A wear-resistant, insulating, and tension-resistant wire clamp, characterized in that: It is prepared by the preparation method described in any one of claims 1-9.

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