A tensile resistant composite cable

Abstract

This invention discloses a tensile-resistant composite cable, belonging to the field of composite cable technology. It includes a core layer, an inner tensile-resistant layer, a composite shielding layer, and an outer sheath layer arranged sequentially from the inside out. The core layer consists of a central conductor and multiple cables surrounding the central conductor. The cables include at least one control conductor, multiple power transmission conductors, tensile filler, composite filler, galvanized steel wire, aramid fiber, and insulating rubber arranged sequentially from the inside out. The tensile filler and composite filler serve as the first tensile filler. By setting the first tensile filler composed of the tensile filler and composite filler, and the mesh-like cylindrical structure composed of twisted galvanized steel wire and aramid fiber, a primary and secondary stress system are formed respectively when the composite cable is subjected to tension, thereby improving the tensile performance of the composite cable.

Description

Technical Field

[0001] This invention relates to the field of composite cable technology, and in particular to a tensile-resistant composite cable. Background Technology

[0002] Composite cables are a type of cable that combines optical fiber and electrical cable. They are commonly used in broadband access network systems. The structure of a composite cable typically consists of multiple parts, including an optical fiber core, conductive copper wire, insulation layer, and sheath. Its design aims to achieve multiple functions, such as power transmission, signal communication, and sensing monitoring.

[0003] The tensile structure design of existing composite cables is generally quite simple, and the technical solutions are mostly limited to setting a steel wire reinforcing core at the center of the cable, or simply adding fiber filler to the sheath layer as an auxiliary reinforcement.

[0004] When a cable is stretched, a single central reinforcement structure (such as a central steel wire) will form a stress pattern with the center as the only load-bearing point. When the cable bends, the central reinforcement is often located near the neutral layer of the bend, making it difficult to effectively share the deformation pressure borne by the outer cores. This uneven stress causes the outer cores to bear the stress first, and they are very prone to breakage due to fatigue or overload under long-term operation.

[0005] Furthermore, as a key structure for resisting electromagnetic interference, traditional braided shielding layers (usually made of copper wire braid) are often designed with only their electrical performance in mind. When the composite cable is repeatedly stretched and bent, the copper wire braided layer will bear huge radial and axial stresses, which can easily cause wire breakage, warping, or loosening of the braided structure, resulting in discontinuous shielding and a sharp decline in the shielding effectiveness. Summary of the Invention

[0006] To address the problems of breakage and shielding discontinuity in existing technologies due to fatigue or overload.

[0007] The technical solution provided by this invention is as follows: A tensile-resistant composite cable includes, from the inside out, a core layer, an inner tensile-resistant layer, a composite shielding layer, and an outer sheath layer; The cable core layer includes at least one control core, multiple power transmission cores arranged sequentially from the inside out, tensile filler, composite filler, galvanized steel wire, aramid fiber and insulating rubber filling the space between the control core and the power transmission core. The tensile filler and composite filler serve as the first tensile filler and as the primary force-bearing element, bearing part of the tension when the composite cable is subjected to tension. The inner tensile layer is tightly wrapped around the outside of the cable core layer. The inner tensile layer consists of fiber filler filling the outside of the cable and multiple reinforcing metal plates, composite metal rods and fins set inside the fiber filler. As a second tensile filler and a secondary force-bearing element, the inner tensile layer further prevents the cable from tensile deformation when the composite cable is stretched. The composite shielding layer includes a semi-conductive buffer water-blocking tape wrapped around the outer side of the inner tensile layer and a shielding layer woven around the outer side of the semi-conductive buffer water-blocking tape. The shielding layer is woven from copper wire and composite fiber. The composite shielding layer further enhances the radial tensile strength and axial tensile strength of the cable. The outer sheath layer includes an outer plastic sheath that tightly wraps around the outside of the composite shielding layer, used to provide protection to the outside of the composite cable.

[0008] Preferably, multiple power transmission cores are arranged around the outside of the control core, composite filler is arranged outside the tensile filler to make the outer surface of the tensile filler round, galvanized steel wire and aramid fiber are arranged inside the composite filler, and an adhesive layer is provided between the galvanized steel wire and aramid fiber and the outside of the tensile filler to prevent the galvanized steel wire and aramid fiber from slipping relative to each other on the outside of the tensile filler, and the outside of the insulating rubber composite filler is tightly wrapped.

[0009] Preferably, galvanized steel wire and aramid fiber are twisted together in the outer part of the composite filler at the corresponding position to form a mesh cylinder structure. The galvanized steel wire is equidistantly arranged around the outer part of the composite filler at the corresponding position, and the aramid fiber has a spiral structure. The mesh cylinder structure is woven from galvanized steel wire as longitudinal reinforcing ribs and aramid fiber as transverse reinforcing ribs. The weaving density of the mesh cylinder structure is not less than 80%. The mesh cylinder structure improves the tensile strength of the cable and will not cause permanent deformation when the composite cable is subjected to tensile deformation.

[0010] Preferably, the tensile filler and composite filler are both polyimide fiber ropes impregnated with water-blocking grease, and their cross-sectional area accounts for 25% to 35% of the total cross-sectional area of ​​the cable.

[0011] Preferably, three reinforcing metal plates arranged in a triangle, a composite metal rod located at the center, and fins fixedly installed between the reinforcing metal plates and the composite metal rod at the corresponding positions together constitute an elastic buffer structure, which is disposed between the outer surfaces of adjacent cables.

[0012] Preferably, the reinforcing metal plate is arc-shaped, and the outer arc surfaces of the reinforcing metal plates within the same elastic buffer structure are close to each other. The elastic buffer structure is embedded inside the fiber filler, and the internal gaps of the elastic buffer structure are filled with limiting filler.

[0013] Preferably, copper wire and composite fiber are twisted together on the outside of the semi-conductive buffer water-blocking strip to form a hollow cylindrical structure. The gaps in the hollow cylindrical structure are set as hexagonal honeycomb, and the weaving density of composite fiber and copper wire is 60% to 80%.

[0014] Preferably, an adhesive layer is provided between the hollow cylindrical structure and the semi-conductive buffer water-blocking strip to prevent relative slippage between the hollow cylindrical structure and the semi-conductive buffer water-blocking strip.

[0015] Preferably, the outer plastic sheath is extruded from thermoplastic polyurethane elastomer rubber material, and the inner wall of the outer plastic sheath is embedded with at least one second tensile filler parallel to the axial direction of the composite cable. The second filler is an FRP reinforcing core with an elliptical cross-section, and the number of FRP reinforcing cores is 4 to 8, which are evenly distributed along the circumferential direction of the inner wall of the outer plastic sheath.

[0016] Preferably, the power transmission core is made of multiple strands of oxygen-free copper wire twisted together.

[0017] The beneficial effects of the technical solution provided by this invention include: By setting up a first tensile filler consisting of tensile filler and composite filler, and a mesh cylinder structure made of galvanized steel wire and aramid fiber, primary and secondary stress systems are formed respectively when the composite cable is subjected to tension, thereby improving the tensile performance of the composite cable. The inner tensile layer is equipped with an elastic buffer structure consisting of reinforcing metal plates, composite metal rods, and fins. This structure can effectively absorb energy when the cable is subjected to radial compression or bending, prevent the cable core from loosening, and enhance the structural stability of the composite cable.

[0018] Among them, the hexagonal honeycomb hollow cylindrical structure design woven from copper wire and PBO fiber in the composite shielding layer not only achieves efficient electromagnetic shielding, but also the high strength characteristics of PBO fiber make the composite shielding layer itself a tensile element, extending the dynamic fatigue life of the composite cable.

[0019] By embedding multiple FRP reinforcing cores into the inner wall of the outer plastic sheath as the outermost reinforcing ribs, the cable is effectively prevented from excessively elongating due to its own weight when laid vertically or overhead over a large span, thereby extending the service life of the composite cable. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall appearance structure of a tensile composite cable provided in an embodiment of the present invention.

[0021] Figure 2 This is a schematic diagram of the overall planar structure of a tensile composite cable provided in an embodiment of the present invention.

[0022] Figure 3 Provided for embodiments of the present invention Figure 2 Enlarged schematic diagram of the structure at point A in the middle.

[0023] Figure 4 This is a cross-sectional schematic diagram of the internal structure of an outer plastic sheath provided in an embodiment of the present invention.

[0024] Figure 5 This is a schematic diagram showing the positional relationship of a semi-conductive buffer water-blocking strip provided in an embodiment of the present invention.

[0025] Figure 6 Provided for embodiments of the present invention Figure 5 Enlarged schematic diagram of the structure at point B.

[0026] Figure 7 This is a schematic diagram of the internal structure of an insulating rubber provided in an embodiment of the present invention.

[0027] Reference numerals: 11. Control wire core; 12. Power transmission wire core; 13. Tensile filler; 14. Composite filler; 15. Galvanized steel wire; 16. Aramid fiber; 17. Insulating rubber; 21. Fiber filler; 22. Reinforcing metal plate; 23. Composite metal rod; 24. Fin; 31. Semi-conductive buffer water-blocking tape; 32. Copper wire; 33. Composite fiber; 41. Outer plastic sheath. Detailed Implementation

[0028] Please see Figures 1 to 7 The present invention provides a tensile composite cable, comprising a core layer, an inner tensile layer, a composite shielding layer, and an outer sheath layer arranged sequentially from the inside out.

[0029] The cable core layer includes at least one control core 11, multiple power transmission cores 12 arranged sequentially from the inside out, tensile filler 13, composite filler 14, galvanized steel wire 15, aramid fiber 16, and insulating rubber 17 filled between the control core 11 and the power transmission core 12. The tensile filler 13 and the composite filler 14 serve as the first tensile filler and as the primary force-bearing element, bearing part of the tension when the composite cable is subjected to tension.

[0030] The inner tensile layer is tightly wrapped around the outside of the cable core layer. The inner tensile layer consists of fiber filler 21 filling the outside of the cable and multiple reinforcing metal plates 22, composite metal rods 23 and fins 24 set inside the fiber filler 21. As a second tensile filler and a secondary force-bearing element, the inner tensile layer further prevents the cable from tensile deformation when the composite cable is stretched.

[0031] The composite shielding layer includes a semi-conductive buffer water-blocking tape 31 wrapped around the outer side of the inner tensile layer and a shielding layer woven around the outer side of the semi-conductive buffer water-blocking tape 31. The shielding layer is woven from copper wire 32 and composite fiber 33. The composite shielding layer further enhances the radial tensile strength and axial tensile strength of the cable.

[0032] The outer sheath layer includes an outer plastic sheath 41 that tightly wraps around the outside of the composite shielding layer, for applying protection to the outside of the composite cable.

[0033] In an alternative embodiment, see [reference] Figure 1 , Figure 2 and Figure 3 Multiple power transmission cores 12 are arranged around the outside of the control core 11. The composite filler 14 is arranged outside the tensile filler 13 to make the outer surface of the tensile filler 13 round. The galvanized steel wire 15 and aramid fiber 16 are arranged inside the composite filler 14, and an adhesive layer is provided between the galvanized steel wire 15 and aramid fiber 16 and the outside of the tensile filler 13 to prevent the galvanized steel wire 15 and aramid fiber 16 from slipping relative to each other on the outside of the tensile filler 13. The insulating rubber 17 is made of thermoplastic polyurethane elastomer rubber extrusion and tightly wraps the outside of the composite filler 14.

[0034] In an alternative embodiment, see [reference] Figure 3 and Figure 7 Galvanized steel wire 15 and aramid fiber 16 are twisted together at corresponding positions outside the composite filler 14 to form a mesh-like cylindrical structure. The galvanized steel wire 15 is equidistantly arranged around the outside of the composite filler 14 at corresponding positions, and the aramid fiber 16 is in a spiral structure. The mesh-like cylindrical structure is woven from galvanized steel wire 15 as longitudinal reinforcing ribs and aramid fiber 16 as transverse reinforcing ribs, with a weaving density of not less than 80%. This mesh-like cylindrical structure can improve the tensile strength of the composite cable and will not cause permanent deformation when the cable is subjected to tensile deformation.

[0035] It should be noted that galvanized steel wire 15 provides a high modulus of elasticity, ensuring that the composite cable does not undergo permanent deformation under extreme tension, while aramid fiber 16 provides dynamic fatigue strength, giving the composite cable a longer service life under repeated bending and stretching.

[0036] It should be noted that when the cable is subjected to axial tensile force, the initial tension is first borne by the first tensile filler (tensile filler 13 and composite filler 14) in the cable core layer. Since tensile filler 13 and composite filler 14 are both polyimide fiber ropes impregnated with water-blocking grease, they have high modulus characteristics and can absorb some energy in the early stage of tension to prevent stress from acting directly on the core.

[0037] Meanwhile, as the tensile force increases, the mesh cylinder structure of the inner tensile layer begins to play its role. The galvanized steel wire 15 acts as a longitudinal reinforcing rib, bearing the main axial tensile force. The high elastic modulus of the mesh cylinder structure material itself ensures that the composite cable does not undergo permanent deformation under extreme tension. In addition, the aramid fiber 16 acts as a transverse reinforcing rib, distributing the longitudinal stress evenly throughout the circumference and avoiding stress concentration.

[0038] In an optional embodiment, both the tensile filler 13 and the composite filler 14 are polyimide fiber ropes impregnated with water-blocking grease, and their cross-sectional area accounts for 25% to 35% of the total cross-sectional area of ​​the cable. The polyimide fiber has excellent water resistance and UV resistance and is suitable for humid environments.

[0039] In an alternative embodiment, see [reference] Figure 2 and Figure 4 The three reinforcing metal plates 22 arranged in a triangle, the composite metal rod 23 located at the center, and the fins 24 fixedly installed between the reinforcing metal plates 22 and the composite metal rod 23 at the corresponding positions together constitute an elastic buffer structure. The elastic buffer structure is set between the outer surfaces of adjacent cables. The reinforcing metal plates 22 are arc-shaped, and the outer arc surfaces of the reinforcing metal plates 22 within the same elastic buffer structure are close to each other. The elastic buffer structure is embedded inside the fiber filler 21, and the internal gaps of the elastic buffer structure are filled by limiting filler.

[0040] It should be noted that when the composite cable is subjected to radial compression or bending, the elastic buffer structure can absorb energy through the elastic deformation of the fins 24 to prevent excessive twisting of the cable core. At the same time, the composite metal rod 23 provides axial support and enhances the overall tensile strength.

[0041] It should also be noted that when the tensile force increases further, the elastic buffer structure (reinforcing metal plate 22, composite metal rod 23, and fins 24) inside the inner tensile layer begins to function. At this time, the fins 24 will undergo elastic deformation, and the elastic deformation of the fins 24 absorbs some of the energy. During this process, the composite metal rod 23 provides axial support for the deformation of the fins 24 and the reinforcing metal plate 22. Meanwhile, the reinforcing metal plate 22 converts the radial pressure into circumferential tension along the arc direction through its arc-shaped structure, further dispersing the load.

[0042] In an alternative embodiment, see [reference] Figure 2 and Figure 5 Copper wire 32 and composite fiber 33 are twisted together on the outside of semi-conductive buffer water-blocking tape 31 to form a hollow cylindrical structure. The gaps in the hollow cylindrical structure are set as hexagonal honeycomb. The composite fiber 33 is poly(p-phenylene benzodioxazole) fiber, and its weaving density with copper wire 32 is 60% to 80%. An adhesive layer is provided between the hollow cylindrical structure and the semi-conductive buffer water-blocking tape 31 to prevent relative slippage between the hollow cylindrical structure and the semi-conductive buffer water-blocking tape 31.

[0043] It should be noted that the hexagonal honeycomb structure not only has a good electromagnetic shielding effect, but the honeycomb holes can also provide deformation margin when the cable is bent, avoiding cracking of the shielding layer. The addition of PBO fibers greatly improves the tear resistance and torsion resistance of the shielding layer.

[0044] It should be noted that the semi-conductive buffer water-blocking strip 31 fills the interior of the hollow cylindrical structure, thereby preventing water penetration.

[0045] For electromagnetic interference propagating along the tangential direction, the honeycomb structure provides a longer effective path than the flat structure. During the use of composite cables, electromagnetic waves must propagate along the contour of the honeycomb wall. With the same physical thickness, the honeycomb structure has greater absorption loss of electromagnetic waves, thus providing a better electromagnetic shielding effect.

[0046] In an alternative embodiment, see [reference] Figure 1 , Figure 2 , Figures 4 to 6 The outer plastic sheath 41 is extruded from thermoplastic polyurethane elastomer rubber material. The inner wall of the outer plastic sheath 41 is embedded with at least one second tensile filler parallel to the axis of the composite cable. The second filler is an FRP reinforcing core with an elliptical cross-section. The number of FRP reinforcing cores is 4 to 8, which are evenly distributed along the circumferential direction of the inner wall of the outer plastic sheath 41. The second tensile filler serves as the outermost reinforcing rib, protecting the internal structure and preventing the composite cable from excessively elongating due to its own weight during suspension installation.

[0047] In an optional embodiment, the power transmission core 12 is made of multiple strands of oxygen-free copper wires twisted together, and a central reinforcing member is provided at the center of the power transmission core 12. The central reinforcing member is a carbon fiber composite core rod, which makes the core itself have tensile strength and further improves the overall tensile performance of the composite cable.

[0048] It should be noted that the FRP reinforcing core is distributed along the axial direction and has extremely high tensile modulus, which can withstand the self-weight of the composite cable or external traction force, preventing the outer plastic sheath 41 from elongating excessively.

[0049] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. The scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A tensile-resistant composite cable, characterized in that, include: The cable core layer, inner tensile layer, composite shielding layer, and outer sheath layer are arranged sequentially from the inside out. The cable core layer includes at least one control core (11), multiple power transmission cores (12), tensile filler (13), composite filler (14), galvanized steel wire (15), aramid fiber (16), and insulating rubber (17) arranged sequentially from the inside to the outside. The tensile filler (13) and the composite filler (14) serve as the first tensile filler and as the primary force-bearing element. The inner tensile layer is tightly wrapped around the outside of the cable core layer. The inner tensile layer includes fiber filler (21) filling the outside of the cable and multiple reinforcing metal plates (22), composite metal rods (23) and fins (24) set inside the fiber filler (21). The inner tensile layer serves as a second tensile filler and as a secondary force-bearing element. The composite shielding layer includes a semi-conductive buffer water-blocking tape (31) wrapped around the outside of the inner tensile layer and a shielding layer woven around the outside of the semi-conductive buffer water-blocking tape (31). The shielding layer is woven from copper wire (32) and composite fiber (33). The outer sheath layer includes an outer plastic sheath (41) tightly wrapped around the outside of the composite shielding layer, for applying protection to the outside of the composite cable.

2. The tensile composite cable according to claim 1, characterized in that, Multiple power transmission cores (12) are arranged around the outside of the control core (11). The composite filler (14) is arranged outside the tensile filler (13) to make the outer surface of the tensile filler (13) round. The galvanized steel wire (15) and aramid fiber (16) are arranged inside the composite filler (14). An adhesive layer is provided between the galvanized steel wire (15) and aramid fiber (16) and the outside of the tensile filler (13) to prevent the galvanized steel wire (15) and aramid fiber (16) from slipping relative to each other outside the tensile filler (13). The insulating rubber (17) tightly wraps the outside of the composite filler (14).

3. The tensile composite cable according to claim 2, characterized in that, Galvanized steel wire (15) and aramid fiber (16) are twisted together in the outside of composite filler (14) at corresponding positions to form a mesh cylinder structure. Galvanized steel wire (15) is equidistantly arranged around the outside of composite filler (14) at corresponding positions. Aramid fiber (16) has a spiral structure. The mesh cylinder structure is woven from galvanized steel wire (15) as longitudinal reinforcing ribs and aramid fiber (16) as transverse reinforcing ribs. The weaving density of the mesh cylinder structure is not less than 80%. The mesh cylinder structure improves the tensile strength of the cable and will not undergo permanent deformation when the composite cable is subjected to tensile deformation.

4. The tensile composite cable according to claim 1, characterized in that, The tensile filler (13) and the composite filler (14) are both polyimide fiber ropes impregnated with water-blocking grease, and their cross-sectional area accounts for 25% to 35% of the total cross-sectional area of ​​the cable.

5. The tensile composite cable according to claim 1, characterized in that, The three reinforcing metal plates (22) arranged in a triangle, the composite metal rod (23) located in the center, and the fins (24) fixedly installed between the reinforcing metal plates (22) and the composite metal rod (23) in the corresponding positions together constitute an elastic buffer structure, which is set between the outer surfaces of adjacent cables.

6. The tensile composite cable according to claim 5, characterized in that, The reinforcing metal plate (22) is arc-shaped, and the outer arc surfaces of the reinforcing metal plate (22) within the same elastic buffer structure are close to each other. The elastic buffer structure is embedded inside the fiber filler (21), and the internal gap of the elastic buffer structure is filled by the limiting filler.

7. The tensile composite cable according to claim 1, characterized in that, Copper wire (32) and composite fiber (33) are twisted together on the outside of semi-conductive buffer water-blocking strip (31) to form a hollow cylindrical structure. The gaps in the hollow cylindrical structure are set as hexagonal honeycomb. The weaving density of composite fiber (33) and copper wire (32) is 60% to 80%.

8. The tensile composite cable according to claim 7, characterized in that, An adhesive layer is provided between the hollow cylindrical structure and the semi-conductive buffer water-blocking strip (31) to prevent relative slippage between the hollow cylindrical structure and the semi-conductive buffer water-blocking strip (31).

9. The tensile composite cable according to claim 1, characterized in that, The outer plastic sheath (41) is extruded from thermoplastic polyurethane elastomer rubber material. The inner wall of the outer plastic sheath (41) is embedded with at least one second tensile filler parallel to the axial direction of the composite cable. The second filler is an FRP reinforcing core with an elliptical cross-section. The number of FRP reinforcing cores is 4 to 8, and they are evenly distributed along the circumferential direction of the inner wall of the outer plastic sheath (41).

10. The tensile composite cable according to claim 1, characterized in that: The power transmission core (12) is made of multiple strands of oxygen-free copper wire twisted together.

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