Highly abrasion resistant flame retardant photovoltaic cable

Abstract

The application discloses a kind of high wear-resistant flame-retardant photovoltaic cables, belong to photovoltaic cable technical field, including flexible torsion-resistant wire core, silicone rubber sheath layer, flame-retardant protective layer and wear-resistant layer, the flexible torsion-resistant wire core is composed of copper conductor and flexible carbon fiber support core, the outer wall of the flexible torsion-resistant wire core is fixedly covered with insulating isolation layer, waterproof and moisture-proof layer is fixed between the insulating isolation layer and silicone rubber sheath layer, the outer wall of the silicone rubber sheath layer is fixedly covered with flame-retardant protective layer, the flame-retardant protective layer is composed of intumescent graphite flame-retardant layer, glass fiber tape flame-retardant layer and ceramic silicon rubber fireproof layer, the flame-retardant protective layer and wear-resistant layer are fixedly covered with corrosion-resistant isolation layer, the outer wall of the wear-resistant layer is mounted with evenly distributed wear-resistant ribs and insecticide filling layer, the present application has the technical effects of flexible torsion-resistant, multi-layer active high-efficiency flame-retardant, high wear-resistant weather-resistant, waterproof and insect-proof.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic cable technology, and in particular relates to a high wear-resistant and flame-retardant photovoltaic cable. Background Technology

[0002] Photovoltaic cables are a crucial and indispensable component in solar photovoltaic (PV) power generation systems. Typically, the low-voltage direct current (DC) generated by PV power generation is converted into alternating current (AC) before being output. The cable connecting the PV modules to the AC / DC inverter is called a PV cable. Therefore, as the backbone of power transmission in PV power generation facilities, PV cables directly affect the safety, reliability, and sophistication of the solar PV power generation system. Because PV cables are often exposed outdoors for extended periods, they face complex conditions such as wind and sand erosion, mechanical crushing, high and low temperature cycling, ultraviolet radiation, moisture intrusion, and chemical corrosion. Therefore, stringent requirements are placed on their wear resistance, flame retardancy, torsional and bending resistance, weather resistance, and waterproofing properties.

[0003] To address this, Chinese Patent CN218957434U discloses a high wear-resistant and flame-retardant photovoltaic cable, comprising a photovoltaic cable body, a cable core disposed inside the photovoltaic cable body, an anti-bending rod disposed at the center of the photovoltaic cable body, a polyethylene wrapping film disposed on the outside of the photovoltaic cable body, and a rubber filler 1 disposed in the gap between the photovoltaic cable body and the polyethylene wrapping film. By placing the cable core inside the photovoltaic cable body, better protection can be achieved, thereby preventing the cable core from shifting. Furthermore, by placing the anti-bending rod at the center of the three photovoltaic cable bodies, a good support and fixation effect is achieved, and bending and torsion resistance is achieved. In addition, the combination of the anti-bending rod, the polyethylene wrapping film, the first rubber filler, and the second rubber filler effectively improves the torsion and bending resistance of the photovoltaic cable.

[0004] However, the aforementioned device uses a single mineral flame-retardant layer, which can only achieve passive flame retardancy. It cannot quickly suppress the spread of fire in the early stages of a fire, and its performance deteriorates significantly after long-term use. The flame-retardant response is sluggish and the effect is poor. Furthermore, the rigid triangular anti-bending rod can easily lead to a decrease in cable flexibility, making it easy to break during laying and easily squeezing the internal wire core, causing insulation damage and affecting the cable's efficiency and lifespan. Summary of the Invention

[0005] To address the problems of existing technologies, this invention provides a high-wear-resistant and flame-retardant photovoltaic cable. It possesses advantages such as flexibility, torsion and bending resistance, multi-layered active and efficient flame retardancy, high wear and weather resistance, and waterproofing and insect resistance. This solves the problems of delayed and poor flame-retardant response, reduced cable flexibility, easy breakage during laying, and easy compression of the internal core causing insulation damage, thus affecting the cable's efficiency and lifespan. This invention, through a design approach of multi-material synergy, multi-structure composite, and multi-functional integration, optimizes all levels from the core, insulation, protection, and outer sheath, achieving long-term stable operation of the photovoltaic cable in extreme outdoor environments.

[0006] This invention provides a high wear-resistant and flame-retardant photovoltaic cable, comprising a flexible anti-torsion core, a silicone rubber sheath layer, a flame-retardant protective layer, and a wear-resistant layer. The flexible anti-torsion core is composed of a copper conductor and a flexible carbon fiber support core. The flexible carbon fiber support core replaces the traditional rigid support component, maintaining excellent flexibility while ensuring mechanical strength, thus fundamentally solving the problems of cable brittleness and easy breakage, and core compression. The outer wall of the flexible anti-torsion core is fixedly covered with an insulating layer made of high-grade cross-linked polyethylene, providing dual protection of electrical insulation and mechanical protection. A waterproof and moisture-proof layer is filled and fixed between the insulating layer and the silicone rubber sheath layer. The waterproof and moisture-proof layer adopts a completely dense filling process to construct a fully sealed waterproof system. The outer wall of the silicone rubber sheath layer is fixedly covered with a flame-retardant protective layer, which is composed of an expanded graphite flame-retardant layer, a glass fiber tape flame-retardant layer, and a ceramicized silicone rubber fireproof layer. The three-layer flame-retardant structure forms a "rapid expansion + structural reinforcement + high-temperature ceramicization" structure. The active synergistic flame-retardant system significantly improves the flame-retardant response speed and fire resistance time; an anti-corrosion isolation layer is fixedly wrapped between the flame-retardant protective layer and the wear-resistant layer, which resists outdoor acid, alkali and salt spray corrosion and extends the aging life of the cable; the outer wall of the wear-resistant layer is equipped with uniformly distributed wear-resistant ridges and an insect repellent filling layer; the wear-resistant ridges provide surface wear-resistant protection, and the insect repellent provides long-term insect prevention, integrating dual functions into the outer sheath.

[0007] In a preferred embodiment of the present invention, the flexible carbon fiber support core is made of high-strength flexible carbon fiber. The flexible carbon fiber support core is configured as multiple strands spirally wound and wrapped around the outer wall of the copper conductor. The insulating layer is cross-linked polyethylene and is fixedly wrapped around the outer wall of the flexible carbon fiber support core. The multi-strand spiral winding structure can evenly distribute torsional and bending forces to each carbon fiber filament, avoiding stress concentration. At the same time, the high elasticity of carbon fiber allows it to quickly rebound after bending, maintaining the roundness of the cable.

[0008] This design allows the multi-strand spirally wound flexible carbon fiber support core to provide the cable with excellent flexibility, torsional and bending resistance while ensuring high-strength support. The minimum bending radius of the cable can reach several times its own outer diameter, which is far superior to traditional rigid support cables, making it suitable for laying in confined spaces and complex terrains. The cross-linked polyethylene insulation layer can effectively isolate the conductor core, improve electrical insulation performance and mechanical protection, and prevent conductor core displacement or insulation damage. During long-term operation, the conductor core does not shift or experience insulation wear, and the electrical performance is stable and reliable.

[0009] Preferably, the waterproof and moisture-proof layer is made of polytetrafluoroethylene (PTFE). The waterproof and moisture-proof layer has evenly distributed installation notches, and a wire mesh reinforcing frame is fixedly connected to each notch. Evenly distributed rubber reinforcing columns are fixedly connected inside the wire mesh reinforcing frame. The wire mesh reinforcing frame is located between the adjacent end faces of the insulating layer and the silicone rubber sheath layer. The chemical inertness of PTFE gives it three functions: waterproof, moisture-proof, and corrosion-resistant. The wire mesh and rubber columns form a "rigid-flexible composite reinforcing structure," providing rigid resistance to crushing and flexible impact cushioning.

[0010] Through this design, PTFE possesses excellent waterproof, moisture-proof, and chemical stability, resisting outdoor moisture intrusion and chemical corrosion. It maintains stable performance even in coastal high-salt spray, industrial pollution areas, and acidic or alkaline soil environments. The steel wire mesh reinforcing frame and rubber reinforcing columns form a composite reinforcing structure, which not only improves the overall mechanical strength of the cable and resists damage from external forces such as crushing and pulling, but also buffers and absorbs shocks to prevent impact damage to the internal core. At the same time, it does not affect the bending flexibility of the cable. The cable can withstand high-intensity radial pressure without internal structural deformation, meeting the requirements for use in scenarios involving vehicle crushing and heavy object pressure.

[0011] In a preferred embodiment of the present invention, the expanded graphite flame-retardant layer, the glass fiber tape flame-retardant layer, and the ceramicized silicone rubber fireproof layer are sequentially wrapped and fixedly connected from the inside out, and the expanded graphite flame-retardant layer is an expanded graphite flame-retardant elastomer. The three flame-retardant layers each perform their respective functions and work synergistically to form full-cycle protection from the initial stage of a fire to the continuous combustion.

[0012] This design creates a synergistic flame-retardant system comprised of the expanded graphite flame-retardant layer, the fiberglass tape flame-retardant layer, and the ceramicized silicone rubber fireproof layer. The expanded graphite flame-retardant elastomer expands rapidly upon contact with fire, forming a dense, heat-insulating char layer that blocks oxygen and heat transfer, achieving active flame retardancy in the early stages of a fire. Its rapid expansion and dense char layer can block flame propagation within seconds. The fiberglass tape flame-retardant layer enhances the structural stability of the char layer, preventing it from detaching. It does not melt or shrink at high temperatures, firmly fixing the expanded char layer and maintaining the integrity of the heat insulation barrier. The ceramicized silicone rubber fireproof layer ceramicizes at high temperatures, forming a hard, fire-resistant shell, further improving fire resistance and insulation performance. Its flame-retardant response is faster and its effect is more durable, effectively suppressing the spread of fire. The overall fire resistance time can reach several hours, meeting the highest level of fire safety requirements for photovoltaic power plants.

[0013] In a preferred embodiment of the present invention, the anti-corrosion isolation layer is made of polyamide, and a reflective aluminum foil sunscreen layer is wrapped and fixed between the anti-corrosion isolation layer and the ceramicized silicone rubber fireproof layer. The reflective aluminum foil and the anti-corrosion layer form a "double-layer weather-resistant protection", with the inner layer resisting ultraviolet rays and the outer layer resisting chemical corrosion, comprehensively resisting outdoor aging factors.

[0014] This design allows the polyamide anti-corrosion isolation layer to resist outdoor acid and alkali chemical corrosion, extending the cable's service life. Its corrosion resistance in soil, sewage, and chemical environments far exceeds that of ordinary polyethylene and PVC sheaths. The reflective aluminum foil sun protection layer can efficiently reflect ultraviolet rays, reduce heat absorption, reduce the impact of high and low temperature cycles on the internal structure, improve weather resistance, and help prevent the outer material from aging and becoming brittle due to ultraviolet radiation.

[0015] In a preferred embodiment of the present invention, both the wear-resistant layer and the wear-resistant ridges are made of diamond-modified polyurethane. The outer wall of the wear-resistant layer has uniformly distributed grooves, and the wear-resistant ridges are fixedly connected to these grooves with their ends extending outwards. Diamond modification significantly improves the wear resistance of the polyurethane, and the ridge structure achieves "contact-type wear resistance," preferentially protecting the main body layer from wear.

[0016] This design significantly enhances the wear resistance of the cable surface through the diamond-modified polyurethane wear-resistant layer and wear-resistant protrusions, effectively resisting wind and sand erosion, mechanical friction and other wear, extending the service life outdoors. The design of the wear-resistant protrusions extending out of the groove can preferentially bear friction during laying and use, protecting the main wear-resistant layer, while enhancing the grip of the cable surface and facilitating laying and fixing; it is less prone to slipping during laying, easier to drag and position, and improves construction efficiency.

[0017] In a preferred embodiment of the present invention, the outer wall of the wear-resistant layer is further provided with a filling cavity, and the insect repellent filling layer is located in the filling cavity. The embedded design of the filling cavity does not occupy external space, does not damage the roundness of the cable, and simultaneously achieves the closed and slow release of the insect repellent.

[0018] This design allows the insect repellent in the filling cavity to slowly release its active ingredients, preventing insects from gnawing at the cable's outer layer and avoiding damage to the protective layer caused by insect infestation. This further enhances the cable's reliability and lifespan in complex outdoor environments. It provides long-lasting repellency against common gnawing pests such as termites and ants, eliminating safety hazards caused by insect damage.

[0019] In a preferred embodiment of the present invention, a silicone rubber cap is bonded and fixed at the opening of the filling cavity, and the silicone rubber cap has several vent holes. This achieves both sealing and slow release, preventing leakage and moisture absorption of the insect repellent while ensuring uniform release of the active ingredient.

[0020] This design allows the silicone rubber cap to seal the filling cavity, preventing the insect repellent from becoming damp and ineffective or leaking. The vent design ensures that the insect repellent is released slowly and evenly, maintaining a long-lasting insect repellent effect while preventing the ingredients from evaporating and being depleted quickly.

[0021] As a preferred embodiment of the present invention, the rubber reinforcing column and the wire mesh reinforcing frame are integrally molded by injection molding; the integrally molded structure has high mechanical bonding strength and excellent vibration and impact resistance.

[0022] The ends of the rubber reinforcing posts are rounded to avoid puncturing adjacent insulation layers and improve the overall safety of the cable.

[0023] As a preferred embodiment of the present invention, the reflective aluminum foil sun protection layer is a double-sided composite aluminum foil. The double-sided composite structure provides more stable reflection, is less prone to oxidation and damage, and has a service life synchronized with the cable body.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] Excellent flexibility and torsional strength: The flexible carbon fiber support core with multi-strand spiral winding ensures torsional and bending resistance while maintaining good cable flexibility, facilitating laying and avoiding insulation damage caused by squeezing the core, thus extending the cable's service life.

[0026] Highly efficient and long-lasting flame retardant effect: The three-layer composite flame retardant system achieves synergistic flame retardancy through active expansion insulation, structural reinforcement, and high-temperature ceramicization. Compared with a single mineral flame retardant layer, it has a faster flame retardant response, effectively suppresses the spread of fire in the early stages of a fire, and exhibits slower performance degradation and stronger fire resistance stability after long-term use.

[0027] Improved wear and weather resistance: The diamond-modified polyurethane wear-resistant layer works synergistically with the raised edges, reflective aluminum foil sun protection layer, and polyamide anti-corrosion layer to significantly improve the cable's wear resistance, sun protection, and corrosion resistance, making it suitable for complex working conditions such as outdoor wind and sand, high and low temperatures, and chemical corrosion.

[0028] Enhanced protection: Integrating waterproof, moisture-proof, mechanical reinforcement, and insect-proof functions, it forms a comprehensive protection system, further extending the service life of the cable in outdoor environments and ensuring the stable operation of the photovoltaic power generation system. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the split structure provided in an embodiment of the present invention;

[0030] Figure 2 This is a schematic diagram of the overall structure provided in an embodiment of the present invention;

[0031] Figure 3 This is provided by the embodiments of the present invention. Figure 2 Enlarged structural diagram at point A in the middle;

[0032] Figure 4 This is a schematic diagram of the front view structure provided in an embodiment of the present invention;

[0033] Figure 5 This is a schematic diagram of the steel wire mesh reinforced frame structure provided in an embodiment of the present invention;

[0034] Figure 6 This is a schematic diagram of the wear-resistant layer structure provided in an embodiment of the present invention.

[0035] In the diagram: 1. Flexible anti-torsion core; 101. Copper conductor; 102. Flexible carbon fiber support core; 2. Insulation layer; 3. Waterproof and moisture-proof layer; 301. Installation notch; 4. Steel wire mesh reinforcing frame; 401. Rubber reinforcing post; 5. Silicone rubber sheath layer; 6. Flame retardant protective layer; 601. Expanded graphite flame retardant layer; 602. Glass fiber tape flame retardant layer; 603. Ceramicized silicone rubber fireproof layer; 7. Wear-resistant layer; 701. Wear-resistant protrusions; 702. Groove; 703. Insect repellent filling layer; 704. Filling cavity; 705. Silicone rubber cap; 706. Ventilation hole; 8. Reflective aluminum foil sun protection layer; 9. Corrosion-resistant isolation layer. Detailed Implementation

[0036] To further understand the invention's content, features, and effects, the following embodiments are provided, and detailed descriptions are given in conjunction with the accompanying drawings.

[0037] The structure of the present invention will now be described in detail with reference to the accompanying drawings.

[0038] refer to Figures 1 to 6As shown in the figure, an embodiment of the present invention provides a high wear-resistant and flame-retardant photovoltaic cable, comprising a flexible anti-torsion core 1, a silicone rubber sheath layer 5, a flame-retardant protective layer 6, and a wear-resistant layer 7. The flexible anti-torsion core 1 is composed of a copper conductor 101 and a flexible carbon fiber support core 102. The copper conductor 101 adopts a multi-strand stranded structure to reduce rigidity and increase flexibility, while reducing heat loss during power transmission. The outer wall of the flexible anti-torsion core 1 is fixedly covered with an insulating isolation layer 2. The insulating isolation layer 2 has a uniform extrusion thickness, is free of core deviation, air bubbles, and impurities, ensuring uniform and stable insulation performance. A waterproof and moisture-proof layer 3 is filled and fixed between the insulating isolation layer 2 and the silicone rubber sheath layer 5. The waterproof and moisture-proof layer 3 completely fills the gap without any cavities, completely blocking moisture. The longitudinal and radial penetration channels are provided. The outer wall of the silicone rubber sheath layer 5 is fixedly covered with a flame-retardant protective layer 6. The flame-retardant protective layer 6 is composed of an expanded graphite flame-retardant layer 601, a glass fiber tape flame-retardant layer 602, and a ceramicized silicone rubber fireproof layer 603. The three layers are concentric and coaxial, with no gaps or misalignments between them, forming a complete and continuous flame-retardant barrier. An anti-corrosion isolation layer 9 is fixedly covered between the flame-retardant protective layer 6 and the wear-resistant layer 7. The anti-corrosion isolation layer 9 has a smooth surface and a low coefficient of friction, making it easy to install by pipe pulling. The outer wall of the wear-resistant layer 7 is equipped with uniformly distributed wear-resistant ridges 701 and an insect repellent filling layer 703. The wear-resistant ridges 701 and the insect repellent filling layer 703 do not interfere with each other, achieving wear resistance and insect repellency functions respectively.

[0039] Specifically, the flexible carbon fiber support core 102 is made of high-strength flexible carbon fiber. The flexible carbon fiber support core 102 is configured as a multi-strand spiral wound covering the outer wall of the copper conductor 101. The insulating layer 2 is cross-linked polyethylene and is fixedly wrapped around the outer wall of the flexible carbon fiber support core 102. The multi-strand spiral winding structure ensures that when the cable is subjected to torsion, bending, or lateral pressure, the stress is evenly absorbed and dispersed by the carbon fiber, preventing it from concentrating at a single point and causing breakage.

[0040] Using the above solution, the multi-strand spirally wound flexible carbon fiber support core 102 ensures high-strength support while giving the cable excellent flexibility and resistance to torsion and bending. The cross-linked polyethylene insulation layer effectively isolates the conductor, improving electrical insulation performance and mechanical protection, and preventing conductor displacement or insulation damage. This structure allows the cable to maintain good conductivity and insulation performance even after repeated bending and torsion, with no risk of wire breakage or insulation damage.

[0041] Specifically, the waterproof and moisture-proof layer 3 is made of polytetrafluoroethylene (PTFE). The waterproof and moisture-proof layer 3 has evenly distributed installation notches 301. A wire mesh reinforcing frame 4 is fixedly connected to each installation notch 301. Evenly distributed rubber reinforcing columns 401 are fixedly connected inside the wire mesh reinforcing frame 4. The wire mesh reinforcing frame 4 is located between the adjacent end faces of the insulating isolation layer 2 and the silicone rubber sheath layer 5. The installation notches 301 precisely position the wire mesh reinforcing frame 4, ensuring that the reinforcing structure is evenly distributed along the circumference and axial direction of the cable.

[0042] Using the above solution, polytetrafluoroethylene (PTFE) possesses excellent waterproof, moisture-proof, and chemical stability, resisting outdoor moisture intrusion and chemical corrosion. The steel wire mesh reinforcing frame 4 and the rubber reinforcing posts 401 form a composite reinforcement structure, which not only improves the overall mechanical strength of the cable, resisting damage from external forces such as crushing and pulling, but also buffers and absorbs shocks, preventing impact damage to the internal conductors, while not affecting the cable's bending flexibility. The composite reinforcement structure ensures that the internal conductors remain intact when the cable is subjected to heavy object crushing, vehicle traffic, and strong wind pulling.

[0043] Specifically, the expanded graphite flame-retardant layer 601, the glass fiber tape flame-retardant layer 602, and the ceramicized silicone rubber fireproof layer 603 are sequentially wrapped and fixedly connected from the inside out. The expanded graphite flame-retardant layer 601 is an expanded graphite flame-retardant elastomer. The elastomer material allows the flame-retardant layer to remain flexible at room temperature, without affecting cable bending, and to quickly activate its flame-retardant function at high temperatures.

[0044] The above-mentioned scheme creates a synergistic flame-retardant system consisting of the expanded graphite flame-retardant layer 601, the glass fiber tape flame-retardant layer 602, and the ceramicized silicone rubber fireproof layer 603. The expanded graphite flame-retardant elastomer rapidly expands upon high temperatures, forming a dense, porous char layer that blocks the transfer of oxygen and heat to the interior, inhibiting the spread of fire. The middle glass fiber tape flame-retardant layer 602 reinforces the char layer structure, preventing the expanded char layer from detaching and failing, and maintaining the heat insulation barrier. The outer ceramicized silicone rubber fireproof layer 603 sinterstens into a hard ceramic shell at high temperatures, further isolating flames and heat, extending the cable's fire resistance time, and achieving multiple layers of protection for the photovoltaic cable, effectively improving its efficiency and lifespan. This three-layer synergistic flame-retardant system solves the core problems of traditional single flame-retardant layers: slow response, easy detachment, and short fire resistance time.

[0045] Specifically, the anti-corrosion isolation layer 9 is made of polyamide, and a reflective aluminum foil sun protection layer 8 is wrapped and fixed between the anti-corrosion isolation layer 9 and the ceramicized silicone rubber fireproof layer 603. The reflective aluminum foil sun protection layer 8 is tightly attached to the outside of the flame-retardant protective layer 6, without wrinkles or damage, maximizing the reflection of ultraviolet rays.

[0046] Using the above solution, the polyamide anti-corrosion isolation layer 9 can resist outdoor chemical corrosion such as acids and alkalis, extending the cable's service life. The reflective aluminum foil sun protection layer 8 can efficiently reflect ultraviolet rays, reduce heat absorption, reduce the impact of high and low temperature cycles on the internal structure, improve weather resistance, and help prevent the outer layer material from aging and becoming brittle due to ultraviolet radiation. The dual weather-resistant design enables the cable to operate stably for a long time in environments with strong ultraviolet radiation at high altitudes, high salt spray at coastal areas, and large temperature differences in deserts.

[0047] Specifically, both the wear-resistant layer 7 and the wear-resistant ridges 701 are made of diamond-modified polyurethane. The outer wall of the wear-resistant layer 7 has evenly distributed grooves 702, and the wear-resistant ridges 701 are fixedly connected in the grooves 702 with their ends extending out of the grooves 702. The grooves 702 and the wear-resistant ridges 701 are press-fitted, ensuring a firm connection and preventing detachment or loosening during long-term use.

[0048] Using the above solution, the diamond-modified polyurethane wear-resistant layer 7 and the wear-resistant protrusions 701 significantly improve the wear resistance of the cable surface, effectively resisting wear from wind and sand erosion, mechanical friction, and other abrasions, extending its outdoor service life. The design of the wear-resistant protrusions 701 extending out of the grooves 702 allows them to preferentially withstand friction during laying and use, protecting the main wear-resistant layer 7, while also enhancing the cable surface's grip and facilitating installation and fixation. The wear-resistant structure minimizes cable wear under desert wind and sand, rock friction, and ground dragging scenarios, significantly extending its lifespan.

[0049] Specifically, the outer wall of the wear-resistant layer 7 is also provided with a filling cavity 704, and the insect repellent filling layer 703 is located in the filling cavity 704. The filling cavity 704 has a precise volume, and the insect repellent is densely filled without gaps or omissions.

[0050] Using the above solution, the insect repellent in the 704 filling cavity can slowly release its active ingredients, preventing insects from gnawing at the cable's outer layer and avoiding damage to the protective layer caused by insect infestation. This further improves the cable's reliability and service life in complex outdoor environments. The insect-proof function solves the industry problem of insect damage caused by direct burial and exposure to dark and damp environments.

[0051] Specifically, a silicone rubber cap 705 is bonded and fixed to the opening of the filling cavity 704, and the silicone rubber cap 705 has a plurality of vent holes 706. The vent holes 706 are small in diameter and evenly distributed, so as to achieve a slow release of a small amount of insect repellent.

[0052] Using the above solution, the silicone rubber cap 705 seals the filling cavity 704, preventing the insect repellent from becoming damp, losing its effectiveness, or leaking. The vent 706 design ensures the slow and even release of the insect repellent, maintaining a long-lasting insect-repellent effect while preventing the ingredients from rapidly evaporating and being depleted. The sealed, slow-release structure ensures a long-term stable insect-repellent effect, eliminating the need for replenishment.

[0053] Working principle of the invention:

[0054] During use, the multi-strand spirally wound flexible carbon fiber support core 102 provides high-strength flexible support. Combined with the composite structure of the steel wire mesh reinforcing frame 4 and rubber reinforcing columns 401, it disperses stress through the elastic deformation of the carbon fiber and the buffering effect of the rubber columns when subjected to torsion, bending, or mechanical crushing, preventing cable breakage or damage to the internal core insulation. The flexible support and composite reinforcing structure work synergistically to achieve dual mechanical protection of "flexible torsional resistance + rigid compressive resistance," adaptable to various mechanical stress scenarios. The polytetrafluoroethylene waterproof and moisture-proof layer 3 isolates water vapor and chemical corrosion, protecting the internal core from moisture and corrosion; the fully enclosed waterproof structure eliminates the risk of moisture-induced short circuits in waterlogged, high-humidity, and directly buried underground environments. The reflective aluminum foil sunscreen layer 8 reflects ultraviolet rays, reduces heat absorption, and mitigates the aging effects of high and low temperature cycles on materials; efficient sun protection lowers the cable surface temperature and slows down the aging rate of polymer materials. The polyamide anti-corrosion isolation layer 9 further resists outdoor acid and alkali chemical corrosion, extending cable life; the anti-corrosion layer is suitable for highly corrosive environments such as saline-alkali land, chemical industrial zones, and coastal areas. The diamond-modified polyurethane wear-resistant layer 7 and wear-resistant ridges 701 preferentially withstand external wear such as wind, sand, and friction, further protecting the internal structure; the wear-resistant structure significantly reduces the outdoor wear rate and extends the service life. The insect repellent in the filling cavity 704 is slowly released through the vents 706 of the silicone rubber cap 705, preventing insects from gnawing on the outer layer; long-lasting insect protection prevents insect damage and improves suitability for underground and dark environments.

[0055] In the event of a fire: the inner layer of expanded graphite flame-retardant elastomer expands rapidly at high temperatures, forming a dense, porous char layer that blocks the transfer of oxygen and heat to the interior, inhibiting the spread of fire; the middle layer of glass fiber with a flame-retardant layer 602 enhances the char layer structure, preventing the expanded char layer from falling off and failing, and maintaining the heat insulation barrier; the outer layer of ceramicized silicone rubber fireproof layer 603 is sintered at high temperatures into a hard ceramic shell, further isolating flames and heat, extending the fire resistance time of the cable. The three-layer flame-retardant structure forms full-cycle flame protection, maximizing the power supply safety and equipment integrity of the photovoltaic system in the event of a fire.

[0056] This invention comprehensively addresses the performance shortcomings of traditional photovoltaic cables through eight core technology upgrades: flexible core reinforcement, reliable insulation protection, waterproof and moisture-proof sealing, mechanical rigidity and flexibility enhancement, multi-layer synergistic flame retardancy, weather resistance, corrosion resistance and sun protection, highly wear-resistant surface layer, and long-lasting insect prevention. It achieves multi-faceted and all-round protection for photovoltaic cables, effectively improving their efficiency, safety stability and service life in complex and harsh outdoor environments. It fully meets the long-term reliable operation requirements of various photovoltaic systems, such as large-scale ground-mounted photovoltaic power stations, distributed photovoltaics, fishery-photovoltaic complementary systems, agricultural-photovoltaic complementary systems, and mountain photovoltaics.

[0057] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0058] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high wear-resistant and flame-retardant photovoltaic cable, characterized in that: The device includes a flexible anti-torsion core (1), a silicone rubber sheath layer (5), a flame-retardant protective layer (6), and a wear-resistant layer (7). The flexible anti-torsion core (1) is composed of a copper conductor (101) and a flexible carbon fiber support core (102). The outer wall of the flexible anti-torsion core (1) is fixedly covered with an insulating isolation layer (2). The insulating isolation layer (2) and the flexible anti-torsion core (1) are bonded together by a thermal bonding process. A waterproof and moisture-proof layer is filled and fixed between the insulating isolation layer (2) and the silicone rubber sheath layer (5). (3) The outer wall of the silicone rubber sheath layer (5) is fixedly covered with a flame-retardant protective layer (6). The flame-retardant protective layer (6) is composed of an expanded graphite flame-retardant layer (601), a glass fiber tape flame-retardant layer (602), and a ceramicized silicone rubber fireproof layer (603). An anti-corrosion isolation layer (9) is fixedly covered between the flame-retardant protective layer (6) and the wear-resistant layer (7). The outer wall of the wear-resistant layer (7) is equipped with uniformly distributed wear-resistant ridges (701) and an insect repellent filling layer (703).

2. The high wear-resistant and flame-retardant photovoltaic cable as described in claim 1, characterized in that: The flexible carbon fiber support core (102) is made of high-strength flexible carbon fiber. The flexible carbon fiber support core (102) is configured to be multi-stranded and spirally wrapped around the outer wall of the copper conductor (101). The multi-strand carbon fiber winding pitch ratio is 10:1 to 15:

1. The spiral direction is opposite to the twisting direction of the copper conductor to improve the resistance to torsion and lateral pressure. The insulating isolation layer (2) is cross-linked polyethylene and is fixedly wrapped around the outer wall of the flexible carbon fiber support core (102).

3. The high wear-resistant and flame-retardant photovoltaic cable as described in claim 2, characterized in that: The waterproof and moisture-proof layer (3) is made of polytetrafluoroethylene. The waterproof and moisture-proof layer (3) has uniformly distributed installation notches (301). The installation notches (301) are strip-shaped and their cross-sections are rectangular or elliptical. A steel wire mesh reinforcing frame (4) is fixedly connected to the installation notch (301). A uniformly distributed rubber reinforcing column (401) is fixedly connected inside the steel wire mesh reinforcing frame (4). The steel wire mesh reinforcing frame (4) is located between the near end faces of the insulating isolation layer (2) and the silicone rubber sheath layer (5).

4. The high wear-resistant and flame-retardant photovoltaic cable as described in claim 3, characterized in that: The expanded graphite flame retardant layer (601), the glass fiber tape flame retardant layer (602), and the ceramicized silicone rubber fireproof layer (603) are sequentially wrapped and fixedly connected from the inside to the outside. The expanded graphite flame retardant layer (601) is an expanded graphite flame retardant elastomer.

5. A high wear-resistant and flame-retardant photovoltaic cable as described in claim 3, characterized in that: The anti-corrosion isolation layer (9) is made of polyamide, and a reflective aluminum foil sunscreen layer (8) is wrapped and fixed between the anti-corrosion isolation layer (9) and the ceramicized silicone rubber fireproof layer (603).

6. The high wear-resistant and flame-retardant photovoltaic cable as described in claim 3, characterized in that: The wear-resistant layer (7) and the wear-resistant protrusion (701) are both made of diamond-modified polyurethane. The outer wall of the wear-resistant layer (7) is provided with uniformly distributed grooves (702). The depth of the grooves (702) is 1 / 3 of the thickness of the wear-resistant layer (7), and its width matches the wear-resistant protrusion (701). The wear-resistant protrusion (701) is fixedly connected in the groove (702) and its end extends out of the groove (702).

7. A high wear-resistant and flame-retardant photovoltaic cable as described in claim 3, characterized in that: The outer wall of the wear-resistant layer (7) is also provided with a filling cavity (704), and the insect repellent filling layer (703) is located in the filling cavity (704).

8. The high wear-resistant and flame-retardant photovoltaic cable as described in claim 7, characterized in that: A silicone rubber cap (705) is bonded and fixed at the opening of the filling cavity (704), and the silicone rubber cap (705) has several vent holes (706).

9. A high wear-resistant and flame-retardant photovoltaic cable as described in claim 7, characterized in that: The rubber reinforcing column (401) and the wire mesh reinforcing frame (4) are integrally formed by injection molding; The end of the rubber reinforcing column (401) is arc-shaped.

10. A high wear-resistant and flame-retardant photovoltaic cable as described in claim 7, characterized in that: The reflective aluminum foil sun protection layer (8) is a double-sided composite aluminum foil.

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