Low-voltage large-current power cable with dynamic heat dissipation

Abstract

The invention relates to the technical field of power cables, in particular to a dynamic heat dissipation low-voltage large-current power cable which comprises a conductor layer, an inner insulating layer and an outer insulating layer. An accommodating cavity is formed between the inner insulating layer and the outer insulating layer; an armor layer is arranged on the inner wall of the accommodating cavity; a thermal expansion unit is arranged in the accommodating cavity; the thermal expansion unit comprises an outer metal expansion layer and an inner metal expansion layer. During low-current operation, the thermal expansion unit is in a non-expansion state, and the cable naturally dissipates heat and keeps good flexibility through the outer insulating layer and the inner insulating layer; during large-current operation, the diameter of the thermal expansion unit is increased, the thermal expansion unit abuts against the inner wall of the containing cavity and the armor layer, a plurality of efficient thermal channels are formed through the high thermal conductivity of metal materials, and internal heat is rapidly conducted out. According to the cable, adaptive adjustment of heat dissipation efficiency and use performance is realized through a dynamic heat dissipation structure, mechanical strength, insulation reliability and laying convenience are considered, and the cable is suitable for various low-voltage large-current transmission scenes.

Description

Technical Field

[0001] This invention relates to the field of power cable technology, and specifically to a low-voltage, high-current power cable with dynamic heat dissipation. Background Technology

[0002] In the field of power transmission, low-voltage high-current power cables are widely used in industrial production, urban power distribution networks, large buildings, and many other scenarios. Their safe and stable operation is directly related to the reliability of the power system and the normal operation of electrical equipment. With the continuous growth of social electricity demand, the transmission capacity of low-voltage high-current power cables is constantly increasing. The Joule heat generated by the conductor during the energization process is also increasing significantly. Heat dissipation has become a key factor restricting the performance and service life of the cables.

[0003] Existing armored cables generally embed the armor layer inside the insulation layer near the center of the cable. Its core function is to enhance the mechanical strength of the cable to resist damage from external impacts, tension, etc. during laying and use.

[0004] However, this structural design has significant drawbacks in terms of heat dissipation: On the one hand, the insulation layer of cables is mostly made of polymer materials such as rubber and cross-linked polyethylene. These materials typically have low thermal conductivity, making it difficult for the heat generated by the conductor to be quickly transferred outwards. This easily leads to heat accumulation inside the cable, causing the cable's operating temperature to rise. On the other hand, the single conductor-insulation-outside heat dissipation path is fixed and inefficient, making it impossible to dynamically adjust the heat dissipation capacity according to the actual operating load of the cable. When the cable is in a high-current, high-temperature operating state for a long time, the excessively high temperature will accelerate the aging and degradation of the insulation layer, reduce its insulation performance, and even cause safety hazards such as insulation breakdown and short circuits. At the same time, it will also lead to an increase in conductor resistance, increasing power transmission loss. When operating at low current, the cable in the traditional structure has poor flexibility, which brings inconvenience to laying, bending and other construction operations. Moreover, it maintains a fixed structural state when high-intensity heat dissipation is not required, lacking adaptability. Summary of the Invention

[0005] The purpose of this invention is to overcome the above-mentioned shortcomings and provide a low-voltage, high-current power cable with dynamic heat dissipation.

[0006] To achieve the above objectives, the specific solution of the present invention is as follows: a low-voltage high-current power cable with dynamic heat dissipation, comprising a conductor layer, an inner insulation layer disposed outside the conductor layer, and an outer insulation layer disposed outside the inner insulation layer; a receiving cavity extending along the length direction is formed between the inner insulation layer and the outer insulation layer; an armor layer is provided on the inner wall of the receiving cavity;

[0007] The cavity is provided with a thermal expansion unit; the thermal expansion unit includes a spiral outer metal expansion layer and a spiral inner metal expansion layer; the inner metal expansion layer is located inside the outer metal expansion layer; the thermal expansion coefficient of the inner metal expansion layer is greater than that of the outer metal expansion layer.

[0008] The present invention is further configured such that both the outer metal expansion layer and the inner metal expansion layer are formed by continuously spirally rolling a flat strip substrate along its length.

[0009] The present invention is further configured such that the cross-sectional shape of the accommodating cavity is circular; and the cross-sectional shape of the thermal expansion unit is annular.

[0010] The present invention is further configured such that a plurality of accommodating cavities are provided between the inner insulating layer and the outer insulating layer along the circumferential direction.

[0011] The present invention is further configured such that multiple accommodating cavities are distributed at equal angles between the inner insulating layer and the outer insulating layer.

[0012] The present invention is further configured such that an inner insulating layer has an inner receiving groove extending along the length direction on its outer side; an outer receiving groove extending along the length direction is formed on its inner side; and the receiving cavity is formed between the inner receiving groove and the outer receiving groove.

[0013] The present invention is further configured such that the cross-sectional shape of the inner accommodating groove and the cross-sectional shape of the outer accommodating groove are both semi-circular.

[0014] The present invention is further configured such that the radius of the content slot is the same as the radius of the outer slot.

[0015] The invention is further configured such that the armor layer is disposed on the inner wall of the outer receiving groove.

[0016] The invention is further configured such that the armor layer is located in the middle of the inner wall of the outer receiving groove.

[0017] The beneficial effects of this invention are as follows: By setting up a thermal expansion unit composed of a double-helix metal expansion layer with a difference in thermal expansion coefficient, the invention achieves dynamic adjustment of heat dissipation capacity. When the cable is running at low current, the thermal expansion unit is in a non-expanded state and separated from the armor layer. Heat is mainly transferred naturally through the inner and outer insulation layers. At this time, the insulation layer maintains good flexibility, which facilitates cable laying and bending operations. When the cable is running at high current, the inner metal expansion layer generates a larger expansion due to its higher thermal expansion coefficient, which drives the diameter of the entire thermal expansion unit to increase and press against the inner wall of the accommodating cavity and the armor layer. Utilizing the thermal conductivity of the metal material, which is much higher than that of the insulation layer, multiple heat dissipation channels are formed inside the cable, which quickly conduct the heat generated by the conductor to the cable surface, significantly improving heat dissipation efficiency, effectively avoiding heat accumulation, reducing the cable operating temperature, and ensuring the safe and stable operation of the cable under high load. Attached Figure Description

[0018] The invention will be further described with reference to the accompanying drawings, but the embodiments in the drawings do not constitute any limitation on the invention. For those skilled in the art, other drawings can be obtained based on the following drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of the present invention;

[0020] Figure 2 This is a front view of the present invention;

[0021] Figure 3 This is a schematic diagram of the thermal expansion unit of the present invention;

[0022] Figure 4 This is a schematic diagram of the structure of the outer insulation layer and the armor layer of the present invention.

[0023] Figure 5 This is a schematic diagram of the structure of the inner insulating layer and the conductor layer of the present invention.

[0024] The components are: 1. Conductor layer; 2. Inner insulation layer; 21. Inner storage groove; 3. Outer insulation layer; 31. Outer storage groove; 4. Storage cavity; 5. Armor layer; 6. Thermal expansion unit; 61. Outer metal expansion layer; 62. Inner metal expansion layer. Detailed Implementation

[0025] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention. It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only.

[0026] like Figure 1-5 As shown, a dynamic heat dissipation low-voltage high-current power cable of this embodiment includes a conductor layer 1, an inner insulation layer 2 disposed outside the conductor layer 1, and an outer insulation layer 3 disposed outside the inner insulation layer 2; a receiving cavity 4 extending along the length direction is formed between the inner insulation layer 2 and the outer insulation layer 3; an armor layer 5 is provided on the inner wall of the receiving cavity 4.

[0027] The cavity 4 is provided with a thermal expansion unit 6; the thermal expansion unit 6 includes a spiral outer metal expansion layer 61 and a spiral inner metal expansion layer 62; the inner metal expansion layer 62 is disposed inside the outer metal expansion layer 61; the thermal expansion coefficient of the inner metal expansion layer 62 is greater than the thermal expansion coefficient of the outer metal expansion layer 61.

[0028] Specifically, in the low-voltage high-current power cable with dynamic heat dissipation described in this embodiment, when the conductor layer 1 is operating at low current, the conductor layer 1 generates less heat, the overall temperature of the power cable is lower, and the thermal expansion unit 6 is in a non-expanded state. At this time, the radius of the thermal expansion unit 6 is small, the thermal expansion unit 6 is separated from the armor layer 5, and the heat of the conductor layer 1 is transferred to the outside through the inner insulation layer 2 and the outer insulation layer 3, causing the inner insulation layer 2 and the outer insulation layer 3 to heat up rapidly, which reduces the stiffness of the insulation material and makes the overall power cable more flexible.

[0029] When conductor layer 1 operates under high current, it generates a significant amount of heat, causing the overall temperature of the power cable to rise. Since the coefficient of thermal expansion of the inner metal expansion layer 62 is greater than that of the outer metal expansion layer 61, the thermal expansion volume of the inner metal expansion layer 62 is greater than that of the outer metal expansion layer 61. The diameter of the spiral thermal expansion unit 6 increases to abut against the inner wall of the accommodating cavity 4 and the armor layer 5. Because both the thermal expansion unit 6 and the armor layer 5 are made of metal, their thermal conductivity is higher than that of the outer insulation layer 3 and the inner insulation layer 2. Furthermore, the spiral thermal expansion unit 6 abuts against the outer insulation layer 3 and the inner insulation layer 2, respectively, forming multiple thermal channels between the outer insulation layer 3, the inner insulation layer 2, and the armor layer 5. This rapidly transfers the heat inside the power cable to the surface of the power cable, significantly enhancing the heat dissipation capacity of the power cable.

[0030] In this embodiment, a low-voltage, high-current power cable with dynamic heat dissipation is provided, wherein both the outer metal expansion layer 61 and the inner metal expansion layer 62 are formed by continuously spirally coiling a flat strip substrate along its length.

[0031] Specifically, in the manufacturing process of the thermal expansion unit 6, the low-voltage high-current power cable with dynamic heat dissipation described in this embodiment first attaches the flat strip-shaped inner metal expansion layer 62 to the inner side of the flat strip-shaped outer metal expansion layer 61, and then uses a continuous spiral winding process to form the thermal expansion unit 6.

[0032] This embodiment employs a continuous spiral rolling process for a flat strip substrate, which balances the structural stability, elastic recovery, and thermal conductivity continuity of the thermal expansion unit 6. Compared to filamentous or block structures, the spiral structure formed by rolling the flat strip substrate has a larger contact area with the inner wall of the accommodating cavity 4 and the armor layer 5, resulting in a smoother heat conduction path and reduced contact thermal resistance during heat transfer. Furthermore, the continuous spiral shape allows the thermal expansion unit 6 to expand uniformly along the circumference when heated, avoiding structural deformation or damage caused by localized stress concentration. Simultaneously, it can smoothly return to its initial state during cooling and contraction, ensuring the repeated and stable realization of the dynamic heat dissipation function.

[0033] This embodiment describes a low-voltage, high-current power cable with dynamic heat dissipation. The accommodating cavity 4 has a circular cross-sectional shape, and the thermal expansion unit 6 has an annular cross-sectional shape. The circular accommodating cavity 4 and the annular thermal expansion unit 6 can form a concentric fit, ensuring that the thermal expansion unit 6 can be uniformly stressed and expand synchronously along the circumference during expansion, avoiding local jamming or insufficient contact caused by irregular cross-sectional shapes. The circumferential integrity of the annular thermal expansion unit 6 allows it to form a continuous circumferential thermally conductive contact surface when it abuts against the inner wall of the accommodating cavity 4 and the armor layer 5, without any thermal dead zones, ensuring that heat is uniformly transferred from the inner insulation layer 2 to the armor layer 5 and the outer insulation layer 3. At the same time, the circular cross-section has better mechanical properties, which can disperse the radial pressure on the power cable during operation, reduce the structural loss of the accommodating cavity 4 and the thermal expansion unit 6, extend the service life of the cable, and the hollow structure of the annular thermal expansion unit 6 can reserve a certain buffer space inside the power cable in the non-expanded state, further improving the flexibility of the cable.

[0034] This embodiment describes a low-voltage, high-current power cable with dynamic heat dissipation. Multiple accommodating cavities 4 are provided circumferentially between the inner insulation layer 2 and the outer insulation layer 3. These cavities 4 are evenly distributed across the radial cross-section of the cable, allowing the thermal expansion unit 6 to simultaneously absorb heat transferred from the inner insulation layer 2 from different directions. This avoids the problems of concentrated heat dissipation and uneven localized temperature caused by a single accommodating cavity 4. Furthermore, the design of multiple accommodating cavities 4 optimizes the radial stress distribution of the power cable, making the mechanical protection of the armor layer 5 more uniform, reducing localized stress during cable bending, and dispersing the radial pressure generated when the thermal expansion unit 6 expands, thus preventing excessive compression of the inner insulation layer 2 and the outer insulation layer 3, balancing heat dissipation performance and structural reliability.

[0035] This embodiment describes a low-voltage, high-current power cable with dynamic heat dissipation. Multiple accommodating cavities 4 are distributed at equal angles between the inner insulation layer 2 and the outer insulation layer 3. This equal-angle distribution ensures uniform mass and stiffness distribution across the radial cross-section of the power cable, preventing issues such as center of gravity shift and bending during cable laying caused by uneven distribution of the accommodating cavities 4, thus improving construction convenience. Furthermore, the equally angled thermal expansion units 6 can uniformly absorb heat from all circumferential directions of the inner insulation layer 2, resulting in a balanced overall temperature field distribution and preventing excessive local heat concentration that accelerates insulation aging. Simultaneously, the equally angled thermal channels allow for more uniform heat dissipation on the surface of the power cable, reducing surface temperature gradients and further improving heat dissipation efficiency. The uniformly distributed structure also provides more comprehensive protection for the armor layer 5, resulting in more balanced stress distribution when resisting external impacts and enhancing the mechanical durability of the power cable.

[0036] This embodiment describes a low-voltage, high-current power cable with dynamic heat dissipation. The inner insulation layer 2 has an inner receiving groove 21 extending along its length on its outer side; the outer insulation layer 3 has an outer receiving groove 31 extending along its length on its inner side; and a receiving cavity 4 is formed between the inner receiving groove 21 and the outer receiving groove 31. Specifically, the inner receiving groove 21 on the outer side of the inner insulation layer 2 and the outer receiving groove 31 on the inner side of the outer insulation layer 3 cooperate with each other, allowing for precise positioning of the receiving cavity 4 during the power cable forming process. This prevents the receiving cavity 4 from shifting or deforming, ensuring the assembly accuracy of the thermal expansion unit 6 and the armor layer 5. Furthermore, the continuous extension of the receiving groove along its length ensures that the thermal expansion unit 6 can be fully assembled along the entire length of the power cable, forming a continuous heat dissipation channel. This avoids heat dissipation breaks caused by discontinuities in the receiving cavity 4, ensuring the consistency of the overall heat dissipation performance of the power cable.

[0037] This embodiment of a low-voltage, high-current power cable with dynamic heat dissipation features a semi-circular cross-sectional shape for both the inner accommodating groove 21 and the outer accommodating groove 31. The two semi-circular grooves, when fitted together, naturally form a circular accommodating cavity 4, which matches the cross-sectional shape of the annular thermal expansion unit 6. This ensures uniform movement space for the thermal expansion unit 6 within the accommodating cavity 4, allowing it to fully conform to the inner wall of the cavity 4 during expansion and avoiding contact gaps caused by shape mismatch. Furthermore, the arc-shaped inner walls of the semi-circular inner accommodating groove 21 and the outer accommodating groove 31 reduce frictional resistance between the thermal expansion unit 6 and the accommodating cavity 4, resulting in smoother movement of the thermal expansion unit 6 during thermal expansion and contraction, thus reducing structural wear.

[0038] This embodiment of a low-voltage, high-current power cable with dynamic heat dissipation features an inner accommodating groove 21 with the same radius as the outer accommodating groove 31. When the inner accommodating groove 21 and the outer accommodating groove 31 are fitted together, they form a circular accommodating cavity 4 with a centrally located center and uniform wall thickness. This ensures that the thermal expansion unit 6 is in a completely concentric installation environment, allowing it to expand uniformly along the circumference when heated. The expansion distance at each location is consistent, preventing uneven contact between the thermal expansion unit 6 and the inner wall due to eccentricity of the accommodating cavity 4, which could lead to thermal dead zones or localized stress concentrations. The uniform structure of the accommodating cavity 4 also ensures that the thickness of the inner insulation layer 2 and the outer insulation layer 3 is consistent around the accommodating cavity 4, resulting in uniform radial insulation performance and mechanical strength distribution of the power cable, further guaranteeing the overall performance stability of the power cable.

[0039] In this embodiment, a low-voltage, high-current power cable with dynamic heat dissipation is provided, wherein the armor layer 5 is disposed on the inner wall of the outer receiving groove 31. In another embodiment, a low-voltage, high-current power cable with dynamic heat dissipation is provided, wherein the armor layer 5 is disposed in the middle of the inner wall of the outer receiving groove 31.

[0040] Specifically, the low-voltage, high-current power cable with dynamic heat dissipation described in this embodiment, by placing the armor layer 5 in the middle of the inner wall of the outer receiving groove 31, can maintain a reasonable distance between the armor layer 5 and the inner insulation layer 2, while reserving sufficient expansion space for the thermal expansion unit 6, ensuring that the thermal expansion unit 6 can expand smoothly and make full contact with the armor layer 5 when heated, without spatial interference; from the perspective of mechanical protection, the middle of the inner wall of the outer receiving groove 31 is a relatively balanced area of ​​force, and placing the armor layer 5 here can more effectively disperse the external impact force and avoid the impact force from concentrating on the edge of the insulation layer and causing damage.

[0041] The above description is only a preferred embodiment of the present invention. Therefore, any equivalent changes or modifications made to the structure, features and principles described in the claims of this patent application are included within the protection scope of this patent application.

Claims

1. A low-voltage, high-current power cable with dynamic heat dissipation, characterized in that: It includes a conductor layer (1), an inner insulating layer (2) disposed outside the conductor layer (1), and an outer insulating layer (3) disposed outside the inner insulating layer (2); a receiving cavity (4) extending along the length direction is formed between the inner insulating layer (2) and the outer insulating layer (3); the inner wall of the receiving cavity (4) is provided with an armor layer (5); The cavity (4) is provided with a thermal expansion unit (6); the thermal expansion unit (6) includes a spiral outer metal expansion layer (61) and a spiral inner metal expansion layer (62); the inner metal expansion layer (62) is located inside the outer metal expansion layer (61); the thermal expansion coefficient of the inner metal expansion layer (62) is greater than that of the outer metal expansion layer (61).

2. The low-voltage, high-current power cable with dynamic heat dissipation according to claim 1, characterized in that: Both the outer metal expansion layer (61) and the inner metal expansion layer (62) are formed by continuously spirally rolling a flat strip substrate along its length.

3. The low-voltage, high-current power cable with dynamic heat dissipation according to claim 1, characterized in that: The accommodating cavity (4) has a circular cross-sectional shape; the thermal expansion unit (6) has an annular cross-sectional shape.

4. A low-voltage, high-current power cable with dynamic heat dissipation according to claim 1, characterized in that: Multiple accommodating cavities (4) are provided between the inner insulating layer (2) and the outer insulating layer (3) along the circumferential direction.

5. A low-voltage, high-current power cable with dynamic heat dissipation according to claim 4, characterized in that: Multiple accommodating cavities (4) are distributed at equal angles between the inner insulating layer (2) and the outer insulating layer (3).

6. A low-voltage, high-current power cable with dynamic heat dissipation according to claim 1, characterized in that: The inner insulating layer (2) has an inner storage groove (21) extending along the length direction on its outer side; the outer insulating layer (3) has an outer storage groove (31) extending along the length direction on its inner side; the storage cavity (4) is formed between the inner storage groove (21) and the outer storage groove (31).

7. A low-voltage, high-current power cable with dynamic heat dissipation according to claim 6, characterized in that: The cross-sectional shape of the content slot (21) and the cross-sectional shape of the outer container slot (31) are both semi-circular.

8. A low-voltage, high-current power cable with dynamic heat dissipation according to claim 7, characterized in that: The radius of the content slot (21) is the same as the radius of the outer content slot (31).

9. A low-voltage, high-current power cable with dynamic heat dissipation according to claim 7, characterized in that: The armor layer (5) is disposed on the inner wall of the outer receiving groove (31).

10. A low-voltage, high-current power cable with dynamic heat dissipation according to claim 9, characterized in that: The armor layer (5) is located in the middle of the inner wall of the outer receiving groove (31).

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