A photovoltaic cable with layered stranded core

Abstract

This invention relates to a photovoltaic cable with layered stranded cores, comprising a central reinforcing unit, layered stranded core units, and an insulation protection unit. The central reinforcing unit, layered stranded core units, and insulation protection units are arranged coaxially from the inside to the outside along the cable's central axis. The central reinforcing unit includes a hollow spiral corrugated interlocking reinforcing core and a central heat dissipation cavity extending along the entire axial direction of the cable. Multiple honeycomb support cores are disposed inside the central heat dissipation cavity. The honeycomb support cores are hollow structures. The hollow spiral corrugated interlocking reinforcing cores are continuous tubular structures wrapped around the outside of the central heat dissipation cavity, with their outer walls having a spiral corrugated structure extending continuously along the cable's axial direction. This invention uses a dual-limiting system to lock the relative positions of each core layer and the central structure, eliminating interlayer sliding and frictional wear, avoiding scratches and breakdowns in the conductor insulation layer, improving the long-term stability of the layered stranded structure, and effectively reducing the cable's operational failure rate.

Description

Technical Field

[0001] This invention relates to the field of wire and cable technology, specifically to a photovoltaic cable with a layered stranded core. Background Technology

[0002] Photovoltaic cables are core components of the power transmission system in photovoltaic power plants, widely used in outdoor photovoltaic support systems, especially in tracking photovoltaic systems, primarily responsible for transmitting DC power between photovoltaic modules and inverters. Operating in complex outdoor environments, they must withstand alternating high and low temperatures, ultraviolet radiation, and wind and sand erosion. Furthermore, they undergo prolonged reciprocating bending movements with the tracking photovoltaic support, placing stringent demands on the stability of the cable's layered stranded structure, insulation reliability, and service life. This directly impacts the long-term stable operation and maintenance cost control of the photovoltaic power plant.

[0003] Photovoltaic cables have a relatively simple structure, mainly consisting of a central reinforcing core, a conductor core, and an outer insulating protective structure. The central reinforcing core is typically a solid or ordinary hollow tubular structure with a smooth outer wall, primarily used to withstand axial tension during cable laying and operation. The conductor core is composed of multiple insulated wires twisted together, used for transmitting photovoltaic power. The outer insulating protective structure wraps around the conductor core, providing electrical insulation and protection against external environmental corrosion. The various structures are connected and positioned only through simple filler materials or flat bonding methods.

[0004] However, existing photovoltaic cables rely solely on simple bonding or filling for positioning between their layers, making it difficult to achieve full-dimensional circumferential and axial dual restraint. This structural design leads to relative sliding and frictional wear between the central reinforcing core and the conductor core, as well as between the layers of the conductor core, during repeated bending with the photovoltaic support or long-term operation. This results in scratches and breakdowns in the conductor insulation layer, reducing the long-term stability of the cable structure, shortening the overall service life of the photovoltaic cable, and failing to meet the requirements for long-term stable operation of photovoltaic power plants. Summary of the Invention

[0005] The purpose of this invention is to provide a photovoltaic cable with layered stranded cores, which aims to improve the problem that in the prior art, the various layers of photovoltaic cables rely only on simple bonding, making it difficult to limit the circumferential and axial directions.

[0006] The objective of this invention is achieved through the following technical solution: a photovoltaic cable with layered stranded core, comprising a central reinforcing unit, a layered stranded core unit, and an insulation protection unit, wherein the central reinforcing unit, the layered stranded core unit, and the insulation protection unit are arranged coaxially from the inside to the outside along the central axis of the cable; The central reinforcing unit includes a hollow spiral corrugated meshing reinforcing core and a central heat dissipation cavity that runs through the entire axial direction of the cable. The central heat dissipation cavity is provided with multiple honeycomb support cores. The honeycomb support cores are hollow structures. The hollow spiral corrugated meshing reinforcing core is a continuous tubular structure wrapped around the outside of the central heat dissipation cavity. Its outer wall is provided with a spiral corrugated structure that extends continuously along the axial direction of the cable. The layered stranded cable core unit includes an inner stranded cable core coaxially wrapped around the outside of the central reinforcing unit, a fully meshing isolation and heat dissipation skeleton coaxially disposed outside the inner stranded cable core, and an outer stranded cable core coaxially wrapped around the outside of the fully meshing isolation and heat dissipation skeleton.

[0007] As a further description of the above technical solution: Both the inner stranded cable core and the outer stranded cable core are made of multiple insulated wire cores with the same structure. Each insulated wire core includes a stranded copper conductor and a conductor insulation layer uniformly extruded on the outer surface of the stranded copper conductor. The insulated wire core of the inner stranded cable core engages with the spiral corrugations on the outer wall of the hollow spiral corrugated interlocking reinforcing core, and the insulated wire core is embedded in the trough of the adjacent spiral corrugations. As a further description of the above technical solution: The fully meshing isolation and heat dissipation frame is divided into an outer frame and an inner frame. The inner circumferential surface of the inner frame is provided with an inner spiral meshing groove that matches the insulating core of the inner stranded cable core. The insulating core of the inner stranded cable core is correspondingly embedded in the inner spiral meshing groove. The outer circumferential surface of the outer frame is provided with an outer spiral meshing groove that matches the insulating core of the outer stranded cable core. The insulating core of the outer stranded cable core is correspondingly embedded in the outer spiral meshing groove. The inner frame is provided with triangular support ribs. The support ribs are provided with axial micro heat dissipation holes that run through the entire axial direction of the cable. As a further description of the above technical solution: The spiral corrugations on the outer wall of the hollow spiral corrugated interlocking reinforcing core have a pitch that is consistent with the stranding pitch of the inner stranded cable core, and the spiral direction is the same as the stranding direction of the inner stranded cable core. As a further description of the above technical solution: The inner spiral meshing groove of the inner skeleton has the opposite spiral direction to the outer spiral meshing groove of the outer skeleton. The spiral direction of the inner spiral meshing groove is consistent with the stranding direction of the inner stranded cable core, and the spiral direction of the outer spiral meshing groove is consistent with the stranding direction of the outer stranded cable core. As a further description of the above technical solution: The stranded copper conductor is formed by regularly stranding multiple soft copper monofilaments, and the conductor insulation layer is an irradiated cross-linked polyethylene insulation layer, which is uniformly covered on the entire outer surface of the stranded copper conductor. As a further description of the above technical solution: The insulation protection unit includes a main insulation layer, a braided reinforcement layer, and a low-smoke halogen-free flame-retardant sheath arranged coaxially from the inside to the outside along the radial direction of the cable. The main insulation layer is uniformly extruded on the outer surface of the outer stranded cable core. The braided reinforcement layer is a mesh braided structure and is coaxially embedded on the outside of the main insulation layer. The low-smoke halogen-free flame-retardant sheath is extruded on the outside of the braided reinforcement layer. As a further description of the above technical solution: The braided reinforcement layer is made of high-strength polyester fiber or galvanized steel wire, and its braided structure is continuously wrapped on the outer surface of the main insulation layer without any broken or skipped wires. As a further description of the above technical solution: The main insulation layer is made of photovoltaic-grade irradiated cross-linked polyethylene material through extrusion molding, and the low-smoke halogen-free flame-retardant sheath is made of photovoltaic-grade low-smoke halogen-free flame-retardant polyolefin material through extrusion molding. Both extend continuously along the entire axial direction of the cable and have uniform thickness.

[0008] Compared with the prior art, the advantages of the present invention are as follows: 1. Through the helical corrugated meshing structure of the hollow helical corrugated meshing reinforcing core, combined with the inner and outer helical meshing grooves of the fully meshing isolation and heat dissipation skeleton, the inner and outer stranded cable cores form a full-dimensional circumferential and axial dual-limiting system, locking the relative position of each layer of cable cores and the central structure, eliminating interlayer relative sliding and friction wear, avoiding scratches and breakdown faults of the conductor insulation layer, improving the long-term stability of the layered stranded structure, effectively reducing the cable operation failure rate, and achieving the beneficial effect of significantly extending the overall service life of photovoltaic cables. 2. Through the central heat dissipation cavity, the axial micro heat dissipation holes in the triangular support ribs, and the through gap between the insulated core and the meshing groove, the heat inside the cable is rapidly conducted out through multiple paths, constructing a three-dimensional heat dissipation network that is connected throughout the axial and radial directions of the cable. Combined with the bending adaptive deformation structure of the spiral corrugated reinforcing core and the triangular support ribs, this reduces the operating temperature rise of the cable, slows down the thermal aging rate of the insulation layer, and improves the bending flexibility and fatigue resistance of the cable. It is suitable for the reciprocating bending conditions of tracking photovoltaic brackets, and improves the cable's environmental adaptability and long-term operational reliability. Attached Figure Description

[0009] Figure 1 This is a schematic diagram of the main body of an embodiment of a photovoltaic cable with layered stranding of the cable core proposed in this invention; Figure 2 This is a schematic diagram of the braided reinforcement layer of a photovoltaic cable with layered stranded cores proposed in this invention; Figure 3 This is a schematic diagram of the outer skeleton structure of a photovoltaic cable with layered stranded cores proposed in this invention; Figure 4This is a schematic diagram of the inner skeleton structure of a photovoltaic cable with layered stranded core proposed in this invention; Figure 5 This is a schematic diagram of the honeycomb support core of a photovoltaic cable with layered stranding proposed in this invention. Figure 6 This is a schematic diagram of the stranded copper conductor of a photovoltaic cable with layered stranding of the cable core proposed in this invention; Figure 7 This is a schematic diagram of the triangular support rib structure of a photovoltaic cable with layered stranded cores proposed in this invention.

[0010] Labeling Explanation: 1. Honeycomb support core; 2. Hollow spiral corrugated interlocking reinforcing core; 3. Stranded copper conductor; 4. Conductor insulation layer; 5. Inner skeleton; 6. Triangular support rib; 7. Axial micro heat dissipation holes; 8. Outer skeleton; 9. Main insulation layer; 10. Braided reinforcing layer; 11. Low smoke halogen-free flame retardant sheath. Detailed Implementation

[0011] The present invention will now be described in detail with reference to the accompanying drawings and embodiments: like Figures 1 to 7 The diagram shows an embodiment of a photovoltaic cable with layered stranded core provided by the present invention. The photovoltaic cable with layered stranded core includes a central reinforcing unit, a layered stranded core unit, and an insulation protection unit. The central reinforcing unit provides axial tensile load and a central positioning reference for the cable. The layered stranded core unit serves as the core conductive body of the cable to achieve stable transmission of photovoltaic power. The insulation protection unit provides all-dimensional electrical insulation and external environmental protection for the cable. The central reinforcing unit, the layered stranded core unit, and the insulation protection unit are arranged coaxially from the inside to the outside along the central axis of the cable.

[0012] The central reinforcement unit includes a hollow spiral corrugated interlocking reinforcement core 2 and a central heat dissipation cavity that runs through the entire axial direction of the cable. The central heat dissipation cavity enables rapid axial discharge of heat accumulated in the center of the cable, forming the main heat dissipation channel of the cable core. The interior of the central heat dissipation cavity is equipped with multiple honeycomb support cores 1. The honeycomb support cores 1 are hollow structures that provide stable support for the central heat dissipation cavity, preventing the heat dissipation channel from being deformed and blocked due to bending or pressure, and ensuring the flow area and unobstructedness of the channel along its entire length. The hollow spiral corrugated interlocking reinforcement core 2 is a continuous tubular structure wrapped around the outside of the central heat dissipation cavity. It bears the overall axial tensile force of the cable, preventing the internal conductor from directly bearing tensile stress and breaking. At the same time, it provides a stable stranding reference for the inner stranded cable core, reducing the overall weight of the cable and improving bending flexibility. Its outer wall is provided with a spiral corrugated structure that extends continuously along the cable axial direction. The spiral corrugated structure and the inner stranded cable core form an interlocking limit, restricting the circumferential rotation and axial movement of the inner cable core, and preventing relative sliding between the inner cable core and the central structure.

[0013] The layered stranded cable core unit includes an inner stranded cable core coaxially wrapped around the outside of the central reinforcing unit, a fully meshing isolation and heat dissipation frame coaxially positioned outside the inner stranded cable core, and an outer stranded cable core coaxially wrapped around the fully meshing isolation and heat dissipation frame. The inner stranded cable core, as one of the core conductive units, works in parallel with the outer stranded cable core to increase the overall current carrying capacity of the cable. The fully meshing isolation and heat dissipation frame achieves physical isolation and bidirectional limiting of the inner and outer stranded cable cores, avoiding relative friction and insulation wear between the cable cores. At the same time, it provides a precise stranding positioning reference for the inner and outer cable cores and provides a structural carrier for the internal heat dissipation channel. The outer stranded cable core, as one of the core conductive units, works with the inner stranded cable core to meet the requirements of high current transmission.

[0014] Both the inner and outer stranded cable cores are composed of multiple insulated cores with identical structures. These insulated cores form the basic conductive unit of the layered stranded cable core, ensuring the stability of power transmission. Each insulated core includes a stranded copper conductor 3 and a conductor insulation layer 4 uniformly extruded onto the outer surface of the stranded copper conductor 3. The stranded copper conductor 3 is composed of multiple soft copper monofilaments regularly stranded together. As the core power transmission carrier of the cable, it enables low-loss continuous transmission of photovoltaic power. The structure of multiple soft copper monofilaments regularly stranded together improves the conductor's flexibility and resistance to bending fatigue. The conductor insulation layer 4 is an irradiated cross-linked polyethylene insulation layer. The conductor insulation layer 4 uniformly covers the entire outer surface of the stranded copper conductor 3, providing individual electrical insulation protection for the stranded copper conductor 3, isolating the live conductor from contact with surrounding structures, and preventing short circuits and leakage faults. It also has excellent temperature and weather resistance, providing basic environmental protection for the internal copper conductor. The insulated core of the inner stranded cable core engages with the spiral corrugations on the outer wall of the hollow spiral corrugated reinforcing core 2, with the insulated core embedded in the troughs of adjacent spiral corrugations. The spiral corrugations on the outer wall of the hollow spiral corrugated reinforcing core 2 have the same pitch as the stranding pitch of the inner stranded cable core, and the spiral direction is the same as the stranding direction of the inner stranded cable core, achieving complete engagement with the inner stranded cable core, eliminating the problem of cable core movement caused by engagement gaps, and ensuring the stability and fit of the limiting structure.

[0015] The fully interlocking heat dissipation frame consists of an outer frame 8 and an inner frame 5. The inner frame 5 supports and limits the inner stranded cable core, providing a forming base for the inner spiral interlocking groove. Together with the triangular support rib 6, it ensures the overall structural strength of the heat dissipation frame. The inner circumferential surface of the inner frame 5 has an inner spiral interlocking groove that matches the insulated core of the inner stranded cable core. This groove precisely engages and fixes the insulated core, limiting circumferential and axial displacement and preventing loose strands or displacement. The insulation of the inner stranded cable core... The wire core is embedded in the inner spiral meshing groove. The outer skeleton 8 supports and limits the outer stranded cable core, providing a forming base for the outer spiral meshing groove, ensuring the roundness and stability of the outer stranded structure. The outer circumferential surface of the outer skeleton 8 is provided with an outer spiral meshing groove that matches the insulated wire core of the outer stranded cable core. The outer spiral meshing groove forms a precise fit and fixation of the insulated wire core of the outer stranded cable core, limiting the circumferential and axial displacement of the outer cable core, and avoiding relative friction between the outer cable core and the inner structure. The insulated wire core of the outer stranded cable core is embedded in the outer spiral meshing groove.

[0016] The inner skeleton 5 is equipped with triangular support ribs 6. The triangular support ribs 6 provide stable radial support for the inner skeleton 5 and the outer skeleton 8, ensuring the overall structural strength of the heat dissipation skeleton and preventing deformation due to compression. At the same time, it provides forming space and structural carrier for the axial micro heat dissipation holes 7. The support ribs are provided with axial micro heat dissipation holes 7 that run through the entire axial direction of the cable. The axial micro heat dissipation holes 7 enable the rapid conduction and axial discharge of heat inside the cable, forming an auxiliary heat dissipation channel inside the cable. Together with the central heat dissipation cavity, they form a three-dimensional heat dissipation system.

[0017] The inner spiral engagement groove of the inner skeleton 5 has the opposite spiral direction to the outer spiral engagement groove of the outer skeleton 8, which is adapted to the opposite stranding direction of the inner and outer cable cores. At the same time, it offsets the residual torsional stress generated after the cable is stranded in layers, avoiding problems such as coiling and self-twisting in the finished cable. The spiral direction of the inner spiral engagement groove is consistent with the stranding direction of the inner stranded cable core, achieving a complete match with the stranding parameters of the inner stranded cable core, ensuring the precise engagement of the inner insulated wire core throughout the entire process, and eliminating the risk of relative slippage between the cable core and the groove. The spiral direction of the outer spiral engagement groove is consistent with the stranding direction of the outer stranded cable core, achieving a complete match with the stranding parameters of the outer stranded cable core, ensuring the precise engagement of the outer insulated wire core throughout the entire process, and improving the limiting stability of the outer stranded structure.

[0018] The insulation protection unit includes a main insulation layer 9, a braided reinforcement layer 10, and a low-smoke halogen-free flame-retardant sheath 11, arranged coaxially from the inside to the outside along the radial direction of the cable. The main insulation layer 9 provides the main electrical insulation protection for the entire layered stranded cable core unit, significantly improving the overall insulation safety margin of the cable, isolating the internal cable core from contact with the external environment, and providing basic mechanical protection for the internal cable core structure. The main insulation layer 9 is uniformly extruded on the outer surface of the outer stranded cable core. The braided reinforcement layer 10 is a mesh braided structure and is coaxially embedded on the outside of the main insulation layer 9, improving the overall mechanical strength of the cable, enhancing the cable's tensile, tear, and impact resistance, preventing damage to the cable from external forces during laying and operation, and ensuring the roundness of the overall cable structure. The low-smoke halogen-free flame-retardant sheath 11 is extruded on the outside of the braided reinforcement layer 10, providing the outermost layer of all-dimensional environmental and mechanical protection for the cable. It is the first barrier against external erosion and also has low-smoke halogen-free flame-retardant characteristics, improving the cable's fire safety level.

[0019] The braided reinforcing layer 10 is made of high-strength polyester fiber or galvanized steel wire, which has excellent mechanical strengthening performance, takes into account both the strengthening effect and the cable flexibility, and is suitable for the laying and operation conditions of photovoltaic cables. Its braided structure continuously covers the outer surface of the main insulation layer 9 without broken wires or skipped wires, achieving uniform coverage of mechanical protection performance throughout the entire length, avoiding the occurrence of local weak points in protection, and ensuring the consistency of the overall strengthening and protection effect.

[0020] The main insulation layer 9 is made of photovoltaic-grade irradiated cross-linked polyethylene material through extrusion molding, possessing excellent temperature resistance, weather resistance, and UV resistance, making it suitable for outdoor photovoltaic applications and ensuring the stability of insulation performance in long-term outdoor environments. The low-smoke halogen-free flame-retardant sheath 11 is made of photovoltaic-grade low-smoke halogen-free flame-retardant polyolefin material through extrusion molding, possessing excellent UV resistance, weather resistance, acid and alkali corrosion resistance, and wear resistance, perfectly adapting to the complex operating environment of outdoor photovoltaic power stations and ensuring the long-term design service life of the cable. Both extend continuously along the entire axial direction of the cable with uniform thickness, achieving uniform and stable protection performance throughout the entire length, avoiding protection failure caused by insufficient local thickness, and ensuring the consistency of protection performance throughout the entire cable section.

[0021] Working principle: First, the hollow honeycomb support core 1 is continuously extruded and molded. Multiple honeycomb support cores 1 are arranged and fixed in parallel along the cable axis to form the internal support structure of the central heat dissipation cavity. Then, the hollow spiral corrugated interlocking reinforcing core 2 is formed through a continuous rolling process, so that the hollow spiral corrugated interlocking reinforcing core 2 forms a continuous tubular structure. A spiral corrugated structure that extends continuously along the cable axis is processed on its outer wall. The arranged honeycomb support cores 1 are coaxially placed into the hollow cavity of the hollow spiral corrugated interlocking reinforcing core 2 to complete the overall prefabrication of the central reinforcing unit.

[0022] Multiple soft copper monofilaments that meet the specifications are selected and stranded into a stranded copper conductor 3 through a standard stranding process. This tightly strands the multiple soft copper monofilaments into a continuous conductor structure. Then, a cross-linked polyethylene conductor insulation layer 4 is uniformly extruded onto the entire outer surface of the stranded copper conductor 3 through an extrusion process. This ensures that the conductor insulation layer 4 completely covers the outer surface of the stranded copper conductor 3, thus completing the prefabrication of a single insulated core. This process is repeated to complete the batch prefabrication of all the insulated cores required for the inner and outer stranded cable cores.

[0023] Multiple prefabricated insulated wire cores are loaded into a CNC winch machine. Using the prefabricated central reinforcing unit as the stranding center reference, the stranding pitch and stranding direction are set to be consistent with the spiral corrugations on the outer wall of the hollow spiral corrugated interlocking reinforcing core 2. The winch machine is started to complete the stranding operation of the inner stranded cable core, so that multiple insulated wire cores are continuously stranded in a spiral shape along the outer circumference of the central reinforcing unit. At the same time, each insulated wire core is embedded in the trough of the adjacent spiral corrugations on the outer wall of the hollow spiral corrugated interlocking reinforcing core 2, thus completing the formation of the inner stranded cable core.

[0024] The continuous molding of a fully meshing heat dissipation skeleton, including an inner skeleton 5, triangular support ribs 6, axial micro heat dissipation holes 7, and an outer skeleton 8, is completed through an integrated extrusion process. An inner spiral meshing groove matching the insulating core of the inner stranded cable core is machined on the inner circumferential surface of the inner skeleton 5, and an outer spiral meshing groove matching the insulating core of the outer stranded cable core is machined on the outer circumferential surface of the outer skeleton 8. An axial micro heat dissipation hole 7 that runs through the entire axial direction of the cable is machined inside the triangular support ribs 6. The molded fully meshing heat dissipation skeleton is then coaxially extruded onto the outer surface of the inner stranded cable core, so that each insulating core of the inner stranded cable core is correspondingly embedded in the inner spiral meshing groove of the inner skeleton 5.

[0025] Multiple prefabricated insulated cores are loaded into a CNC winding machine. The inner core structure, which is wrapped with a fully meshing heat dissipation skeleton, is used as the winding reference. The winding pitch and winding direction are set to be consistent with the outer spiral meshing groove on the outer circumference of the outer skeleton 8. At the same time, the winding direction is set to be opposite to that of the inner core. The winding machine is started to complete the winding operation of the outer core, so that multiple insulated cores are continuously wound in a spiral shape along the outer circumference of the outer skeleton 8. At the same time, each insulated core is embedded into the outer spiral meshing groove of the outer skeleton 8, thus completing the overall forming of the layered winding core unit.

[0026] A photovoltaic-grade irradiated cross-linked polyethylene main insulation layer 9 is uniformly extruded onto the outer surface of the completed outer stranded cable core using an extrusion process, ensuring that the main insulation layer 9 completely covers the entire outer surface of the outer stranded cable core. Then, high-strength polyester fibers or galvanized steel wires are woven into a continuous mesh structure using a braiding device to form a braided reinforcement layer 10. This braided reinforcement layer 10 is coaxially wrapped around the outer surface of the main insulation layer 9. Finally, a photovoltaic-grade low-smoke halogen-free flame-retardant sheath 11 is uniformly extruded onto the outer surface of the braided reinforcement layer 10 using an extrusion process, ensuring that the low-smoke halogen-free flame-retardant sheath 11 completely covers the outer surface of the braided reinforcement layer 10, thus completing the overall molding of the finished cable.

[0027] The finished cable is laid into the corresponding line of the photovoltaic power station. The stranded copper conductors 3 at both ends of the cable are electrically connected to the output end of the photovoltaic module and the input end of the inverter, respectively. The DC power generated by the photovoltaic module is introduced into the stranded copper conductors 3 through the connection points at both ends of the cable. The power is continuously transmitted along the cable axis through multiple stranded copper conductors 3 connected in parallel.

[0028] During cable operation, the heat generated by the stranded copper conductor 3 is partially conducted to the central heat dissipation cavity at the very center of the cable, where it is continuously discharged along the cable axis. Part of the heat is conducted to the triangular support ribs 6 of the fully interlocking isolation heat dissipation frame, where it is continuously conducted and discharged along the cable axis through the axial micro heat dissipation holes 7. Another part of the heat is conducted along the cable axis through the through gap between the insulated wire core and the spiral interlocking groove.

[0029] During cable laying or reciprocating bending along with photovoltaic supports, the inner stranded core and the outer stranded core adapt to each other along the corresponding spiral meshing grooves. The spiral corrugated structure of the hollow spiral corrugated meshing reinforcing core 2 adapts to the corresponding deformation as the cable bends. The triangular support ribs 6 of the fully meshing isolation heat dissipation skeleton adapt to the corresponding deformation as the cable bends, thus completing continuous adaptive adjustment during the cable bending process.

Claims

1. A layered stranded fully meshing adaptive buffer photovoltaic cable, comprising a central reinforcing unit, a layered stranded cable core unit, and an insulation protection unit, characterized in that: The central reinforcing unit, the layered stranded cable core unit, and the insulation protection unit are arranged coaxially from the inside to the outside along the central axis of the cable. The central reinforcement unit includes a hollow spiral corrugated meshing reinforcement core (2) and a central heat dissipation cavity that runs through the entire axial direction of the cable. The interior of the central heat dissipation cavity is provided with multiple honeycomb support cores (1). The honeycomb support core (1) is a hollow structure. The hollow spiral corrugated meshing reinforcement core (2) is a continuous tubular structure wrapped around the outside of the central heat dissipation cavity. Its outer wall is provided with a spiral corrugated structure that extends continuously along the axial direction of the cable. The layered stranded cable core unit includes an inner stranded cable core coaxially wrapped around the outside of the central reinforcing unit, a fully meshing isolation and heat dissipation skeleton coaxially disposed outside the inner stranded cable core, and an outer stranded cable core coaxially wrapped around the outside of the fully meshing isolation and heat dissipation skeleton.

2. The layered stranded fully meshing adaptive buffer photovoltaic cable according to claim 1, characterized in that: Both the inner stranded cable core and the outer stranded cable core are made of multiple insulated wire cores with the same structure. Each insulated wire core includes a stranded copper conductor (3) and a conductor insulation layer (4) uniformly extruded on the outer surface of the stranded copper conductor (3). The insulated wire core of the inner stranded cable core meshes with the spiral corrugations on the outer wall of the hollow spiral corrugated meshing reinforcing core (2), and the insulated wire core is embedded in the trough of the adjacent spiral corrugations.

3. The layered stranded fully meshing adaptive buffer photovoltaic cable according to claim 2, characterized in that: The fully meshing isolation and heat dissipation frame is divided into an outer frame (8) and an inner frame (5). The inner circumferential surface of the inner frame (5) is provided with an inner spiral meshing groove that matches the insulating core of the inner stranded cable core. The insulating core of the inner stranded cable core is embedded in the inner spiral meshing groove. The outer circumferential surface of the outer frame (8) is provided with an outer spiral meshing groove that matches the insulating core of the outer stranded cable core. The insulating core of the outer stranded cable core is embedded in the outer spiral meshing groove. The inner frame (5) is provided with a triangular support rib (6). The support rib is provided with an axial micro heat dissipation hole (7) that runs through the entire axial direction of the cable.

4. The layered stranded fully meshing adaptive buffer photovoltaic cable according to claim 1, characterized in that: The spiral corrugations on the outer wall of the hollow spiral corrugated meshing reinforcing core (2) have a pitch that is consistent with the twisting pitch of the inner stranded cable core, and the spiral direction is the same as the twisting direction of the inner stranded cable core.

5. A layered stranded fully meshing adaptive buffer photovoltaic cable according to claim 3, characterized in that: The inner spiral meshing groove of the inner skeleton (5) has the opposite spiral direction to the outer spiral meshing groove of the outer skeleton (8). The spiral direction of the inner spiral meshing groove is consistent with the stranding direction of the inner stranded cable core, and the spiral direction of the outer spiral meshing groove is consistent with the stranding direction of the outer stranded cable core.

6. A layered stranded fully meshing adaptive buffer photovoltaic cable according to claim 3, characterized in that: The stranded copper conductor (3) is formed by regularly stranding multiple soft copper monofilaments, and the conductor insulation layer (4) is an irradiated cross-linked polyethylene insulation layer, which is uniformly covered on the entire outer surface of the stranded copper conductor (3).

7. A layered stranded fully meshing adaptive buffer photovoltaic cable according to claim 1, characterized in that: The insulation protection unit includes a main insulation layer (9), a braided reinforcement layer (10), and a low-smoke halogen-free flame-retardant sheath (11) arranged coaxially from the inside to the outside along the radial direction of the cable. The main insulation layer (9) is uniformly extruded on the outer surface of the outer stranded cable core. The braided reinforcement layer (10) is a mesh braided structure and is coaxially embedded on the outside of the main insulation layer (9). The low-smoke halogen-free flame-retardant sheath (11) is extruded on the outside of the braided reinforcement layer (10).

8. A layered stranded fully meshing adaptive buffer photovoltaic cable according to claim 7, characterized in that: The braided reinforcing layer (10) is woven from high-strength polyester fiber or galvanized steel wire, and its braided structure continuously covers the outer surface of the main insulation layer (9) without any broken or skipped wires.

9. A layered stranded fully meshing adaptive buffer photovoltaic cable according to claim 7, characterized in that: The main insulation layer (9) is made of photovoltaic-specific irradiated cross-linked polyethylene material through extrusion molding, and the low-smoke halogen-free flame-retardant sheath (11) is made of photovoltaic-specific low-smoke halogen-free flame-retardant polyolefin material through extrusion molding. Both extend continuously along the entire axial direction of the cable and have uniform thickness.

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