Salt mist resistant photovoltaic system specific cable

Abstract

This invention discloses a salt spray resistant photovoltaic system-specific cable, belonging to the field of photovoltaic cable technology, comprising: a protective layer; and an outer protective mechanism. This salt spray resistant photovoltaic system-specific cable, through the use of an anti-compression mechanism, can disperse and absorb concentrated point loads or line loads through the deformation of spring sheets when the cable conductors are subjected to external compression, impact, or bending. These loads are then converted into uniform surface loads by elastic fillers, significantly improving the cable conductors' resistance to compression, impact, and repeated bending, protecting the delicate internal conductors and optical fibers from damage. Through the use of a positioning mechanism, with the cooperation of tension ribs, positioning slots, and hook-ring supports, mutual restraint between multiple cable conductors is achieved, ensuring that the position of each cable conductor is precisely fixed. This prevents relative displacement, wear, or kinking caused by vibration and bending during use, greatly reducing the risk of short circuits and local insulation wear, and ensuring the long-term stability of the electrical connection.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic cable technology, specifically a salt spray resistant photovoltaic system cable. Background Technology

[0002] As a clean and renewable energy solution, photovoltaic power generation systems are rapidly expanding from the conventional, mild terrestrial environments to harsh environments such as coastal areas, tidal flats, islands, and near-shore platforms. These areas are rich in solar resources, but also present complex challenges such as high salinity, high humidity, strong ultraviolet radiation, and frequent mechanical stress. As a key component in photovoltaic systems that connects components and transmits electrical energy and signals, the long-term reliability of cables directly affects the power generation efficiency, operational safety, and lifecycle cost of the entire system.

[0003] Salt spray resistant photovoltaic cables are electrical connection components used in marine photovoltaic power generation. The cables float on the sea surface via buoys to transmit electricity to mining equipment. In such applications, they are often subjected to severe corrosion from strong ultraviolet radiation and high salt pollution, as well as high wind speeds and waves. Therefore, the compressive strength of marine cables needs to be further improved.

[0004] Currently, photovoltaic cables used in such environments mostly adopt a strategy of surface optimization or material upgrades based on conventional structures, such as using more weather-resistant sheath materials or adding an anti-salt spray coating to the outside of the sheath. However, this approach, which focuses on external single protection, has inherent limitations: 1. Thickened sheathing layers designed to improve weather resistance often hinder the dissipation of heat generated by the internal conductors of the cable during operation, leading to heat accumulation, increased insulation temperature, and accelerated aging. 2. When the outer sheath is damaged by mechanical damage, ultraviolet aging or chemical corrosion, salt spray and moisture can easily penetrate along the longitudinal direction of the cable or enter the interior through the gaps in the materials. Traditional structures lack active longitudinal water blocking and internal hydrophobic barriers. Once intruded, moisture will spread rapidly, causing electrochemical corrosion of the metal conductor, a decrease in insulation performance, and even short circuit faults. 3. Existing cable internal structures rely heavily on the material's own elasticity for resistance to pressure, impact, and long-term bending vibration, lacking effective mechanical stress buffering and dispersion mechanisms. Under complex stress, internal conductors and components are prone to relative displacement, compression, or fatigue damage, affecting the stability of electrical connections. 4. The internal conductors of multi-core cables lack effective physical isolation and precise positioning. Under installation dragging, operation vibration or temperature changes, they are prone to mutual friction or displacement, which not only increases the risk of short circuits, but may also lead to local stress concentration and accelerate insulation damage. Summary of the Invention

[0005] The purpose of this invention is to: utilize an anti-compression mechanism to disperse and absorb concentrated point or line loads when cable conductors are subjected to external compression, impact, or bending through the deformation of spring plates, and transform them into uniform surface loads via elastic fillers. This significantly improves the cable conductors' resistance to compression, impact, and repeated bending, protecting the delicate internal conductors and optical fibers from damage. Furthermore, the positioning mechanism, consisting of tension ribs, positioning slots, and hook-ring supports, achieves mutual restraint among multiple cable conductors, precisely fixing the position of each conductor. This prevents relative displacement, wear, or kinking caused by vibration and bending during use, greatly reducing the risk of short circuits and localized insulation wear, and ensuring electrical safety. The long-term stability of the gas connection is achieved by setting an independent heat-conducting layer in the outer protective structure and combining it with a metal mesh to construct an efficient heat path from the inside out. This allows the Joule heat generated by the cable conductor during operation to be quickly and evenly conducted and dissipated into the environment, effectively avoiding heat aging cycles caused by thickening of the outer protective layer. While ensuring excellent weather resistance, this also ensures the stability of the electrical performance and the extension of the cable's lifespan during long-term operation. The hydrophobic layer prevents the lateral diffusion of moisture. Combined with the tightly wrapped structure and the application of potential water-blocking materials, it effectively inhibits the longitudinal spread of salt spray moisture caused by minor damage to the sheath, localizing the risk of intrusion and fundamentally protecting the electrical integrity of the internal conductors and insulation, preventing electrochemical corrosion.

[0006] The technical solution adopted in this invention is as follows: A special cable for salt spray resistant photovoltaic systems, comprising: Protective layer; The outer protective mechanism is located inside the protective layer; The inner protective mechanism is located within the outer protective mechanism; The cable conductors are provided in multiple forms, and all of the multiple cable conductors are installed inside the inner protective mechanism; A pressure-resistant mechanism is provided between the outer protective mechanism and the inner protective mechanism. The pressure-resistant mechanism includes a pressure-resistant spring and an elastic filler. The pressure-resistant spring is installed between the outer protective mechanism and the inner protective mechanism, and the elastic filler is installed between the outer protective mechanism and the inner protective mechanism, and the elastic filler is wrapped around the pressure-resistant spring. A positioning mechanism is located within the inner protective mechanism and is connected to multiple cable conductors. The positioning mechanism includes a base column component, a docking component, and a hook and loop bracket. The base column component is located within the inner protective mechanism. Multiple hook and loop brackets are provided, each set of which is located on the base column component. Multiple sets of docking components are provided, with each set of docking components located on each hook and loop bracket, and each set of docking components is connected to each cable conductor.

[0007] The outer protective structure includes a hydrophobic layer, a thermally conductive layer, a metal mesh, and a wear-resistant layer. The hydrophobic layer is installed within the protective layer, the thermally conductive layer is installed within the hydrophobic layer, the metal mesh is installed within the thermally conductive layer, and the wear-resistant layer is installed within the metal mesh. The inner protective mechanism includes a bushing, a filling material, a tensile reinforcing rib, and a support partition. The bushing is installed inside the compression spring sheet, the filling material is filled inside the bushing, there are two support partitions, which are respectively fixedly connected to both sides inside the bushing, and there are two tensile reinforcing ribs, each of which is installed inside each support partition.

[0008] The base column component includes a tension rib and a positioning groove block. The tension rib is installed at the center of the bushing. Multiple positioning groove blocks are provided, and the multiple positioning groove blocks are fixedly connected to the tension rib at equal intervals. Each hook and ring bracket is snapped into each positioning groove block.

[0009] Each set of docking components includes a docking block and a docking hole. The docking block is fixedly connected to the cable conductor, and the docking hole is opened on the hook and ring bracket and is snapped onto the docking block.

[0010] It also includes an optical fiber mechanism, which is arranged in two groups. Both groups of optical fiber mechanisms are located inside the bushing. Each group of optical fiber mechanisms includes an optical fiber unit line and a support frame. The optical fiber unit line is installed inside the bushing, and the support frame is fixedly connected inside the bushing. The inner wall of the support frame is wrapped around the outer surface of the optical fiber unit line.

[0011] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are: (1) In this invention, by using the anti-compression mechanism, when the cable conductor is subjected to external compression, impact or bending, the concentrated point load or line load can be dispersed and absorbed by the deformation of the spring sheet, and transformed into a uniform surface load by the elastic filler, which significantly improves the cable conductor's resistance to compression, impact and repeated bending, and protects the internal weak conductor and optical fiber from damage.

[0012] (2) In this invention, by using the positioning mechanism, the tension rib, positioning groove block and hook ring bracket work together to achieve mutual restraint between multiple cable conductors, so that the position of each cable conductor is precisely fixed, preventing relative displacement, wear or kinking caused by vibration and bending during use, greatly reducing the risk of short circuit and local insulation wear, and ensuring the long-term stability of electrical connection.

[0013] (3) In this invention, by setting an independent heat-conducting layer in the outer protective structure and combining it with a metal mesh, a highly efficient heat path from the inside to the outside is constructed, which can quickly and evenly export and dissipate the Joule heat generated by the cable conductor during operation to the environment, effectively avoiding the heat aging cycle caused by the thickening of the outer protective layer. While ensuring excellent weather resistance, it also ensures the stability of the electrical performance and the extension of the life of the cable during long-term operation.

[0014] (4) In this invention, the hydrophobic layer prevents the lateral diffusion of moisture. Combined with the tightly wrapped structure and the application of potential water-blocking materials, it effectively inhibits the longitudinal spread of salt spray moisture caused by minor damage to the sheath, localizes the risk of intrusion, and fundamentally protects the electrical integrity of the internal conductor and insulation, preventing electrochemical corrosion. Attached Figure Description

[0015] Figure 1 This is an exploded cross-sectional view of the present invention; Figure 2 This is an exploded view of the present invention; Figure 3 This is a partial cross-sectional view of the present invention; Figure 4 This is a perspective view of the present invention; Figure 5 This is an exploded view of the positioning mechanism of the present invention; Figure 6 This is a perspective view of the positioning mechanism of the present invention; Figure 7 This is an exploded cross-sectional view of the anti-compression mechanism of the present invention; Figure 8 This is an exploded view of the anti-compression mechanism of the present invention.

[0016] The markings in the diagram are: 1. Protective layer; 2. Hydrophobic layer; 3. Thermally conductive layer; 4. Metal mesh; 5. Wear-resistant layer; 6. Compression spring; 7. Bushing; 8. Tension reinforcing rib; 9. Support partition; 10. Cable conductor; 11. Hook and loop bracket; 12. Fiber optic unit line; 13. Support frame; 14. Wrapping filler; 15. Elastic filler; 16. Tensioning rib; 17. Butt joint block; 18. Butt joint hole; 19. Positioning groove block. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0018] Example 1, refer to Figure 1-8 A special cable for salt spray resistant photovoltaic systems, comprising: Protective layer 1; In this embodiment, the protective layer 1 is typically made of polyurethane (PUR), polyvinyl chloride (PVC), or rubber, providing basic protection such as overall mechanical protection, wear resistance, oil resistance, weather resistance, and flame retardancy. The surface of the protective layer 1 is coated with an anti-salt spray layer to improve its anti-salt spray performance.

[0019] Specifically: the outer protective mechanism is located inside the protective layer 1; the outer protective mechanism includes a metal mesh 4, a wear-resistant layer 5, a hydrophobic layer 2, and a thermally conductive layer 3. The hydrophobic layer 2 is installed inside the protective layer 1, the thermally conductive layer 3 is installed inside the hydrophobic layer 2, the metal mesh 4 is installed inside the thermally conductive layer 3, and the wear-resistant layer 5 is installed inside the metal mesh 4.

[0020] In this embodiment: the hydrophobic layer 2 is a tubular body made of hydrophobic material, which actively prevents moisture penetration and diffusion. Even if the sheath has minor damage, it can prevent moisture from spreading longitudinally along the cable, protecting the internal electrical components. The thermally conductive layer 3 is a polymer layer containing highly thermally conductive filler, which efficiently dissipates the heat generated by the internal cable conductors 10 during operation, preventing heat accumulation and excessive temperature rise, which would affect cable performance and service life. The wear-resistant layer 5 can use high-hardness polyurethane, specifically designed for repeated friction and dragging conditions, providing additional wear resistance. The metal mesh 4 can provide electromagnetic shielding, blocking external electromagnetic interference from entering the cable and preventing electromagnetic radiation leakage from inside the cable. Meanwhile, it provides a certain degree of mechanical protection. The independent heat-conducting layer 3, combined with the metal mesh 4, constructs an efficient heat path from the inside out, which can quickly and evenly conduct and dissipate the Joule heat generated by the cable conductor 10 during operation to the environment. This effectively avoids the heat aging cycle caused by the thickening of the outer protective layer 1. While ensuring excellent weather resistance, it ensures the stability of electrical performance and the extension of life of the cable during long-term operation. The hydrophobic layer 2 prevents the lateral diffusion of moisture. Combined with the tightly wrapped structure and the application of potential water-blocking materials, it effectively inhibits the longitudinal spread of salt spray moisture caused by minor damage to the sheath, localizes the risk of intrusion, and fundamentally protects the electrical integrity of the internal conductor and insulation, preventing electrochemical corrosion.

[0021] Specifically: The inner protective mechanism is located within the outer protective mechanism; the inner protective mechanism includes a tension reinforcing rib 8, a support partition 9, a bushing 7, and a wrapping filler 14. The bushing 7 is installed inside the compression spring 6, and the wrapping filler 14 is filled inside the bushing 7. There are two support partitions 9, which are fixedly connected to both sides inside the bushing 7. There are two tension reinforcing ribs 8, and each tension reinforcing rib 8 is installed inside each support partition 9.

[0022] In this embodiment: the bushing 7 completely wraps the cable conductor 10, completing its use. The filling material 14 is used to fill the gaps inside the bushing 7, serving as structural filling and fixing functions. The tension reinforcing rib 8 is made of aramid yarn and high-strength polyester, which is non-conductive and is specifically responsible for bearing the axial tension of the cable during installation and operation, protecting the internal conductors and optical fibers from being pulled apart. The support partition 9 separates the tension reinforcing rib 8, and the tension reinforcing rib 8 supports the hook and loop bracket 11 to ensure its use.

[0023] Specifically: there are multiple cable conductors 10, and all of the multiple cable conductors 10 are installed inside the inner protective mechanism.

[0024] Specifically: The pressure-resistant mechanism is located between the outer protection mechanism and the inner protection mechanism. The pressure-resistant mechanism includes a pressure-resistant spring sheet 6 and an elastic filler 15. The pressure-resistant spring sheet 6 is installed between the outer protection mechanism and the inner protection mechanism, and the elastic filler 15 is installed between the outer protection mechanism and the inner protection mechanism, and the elastic filler 15 is wrapped around the pressure-resistant spring sheet 6. In this embodiment, the compression-resistant spring 6 is bent, which can relieve stress when the cable is subjected to external force. Together with the elastic filler 15, it ensures the safety of the internal cable conductor 10. When the cable conductor 10 is subjected to external compression, impact or bending, it can disperse and absorb the concentrated point load or line load through the deformation of the spring, and transform it into a uniform surface load through the elastic filler 15. This significantly improves the compression resistance, impact resistance and repeated bending resistance of the cable conductor 10, and protects the delicate internal conductors and optical fibers from damage.

[0025] Specifically: A positioning mechanism is located within the inner protective mechanism and is connected to multiple cable conductors 10. The positioning mechanism includes a base column component, a docking component, and a hook and loop bracket 11. The base column component is located within the inner protective mechanism. Multiple hook and loop brackets 11 are provided, each set of which is located on the base column component. Multiple sets of docking components are provided, with each pair of docking components located on each hook and loop bracket 11, and each set of docking components is connected to each cable conductor 10. The base column component includes a tension rib 16 and a positioning groove block 19. The tension rib 16 is installed at the center inside the bushing 7. Multiple positioning groove blocks 19 are provided, and each set of positioning groove blocks 19 is equidistantly fixedly connected to the tension rib 16. Each hook and loop bracket 11 is snapped into each positioning groove block 19. Each set of docking components includes a docking block 17 and a docking hole 18. The docking block 17 is fixedly connected to the cable conductor 10, and the docking hole 18 is opened on the hook and loop bracket 11 and snapped into the docking block 17.

[0026] In this embodiment: the tension rib 16 improves the overall structural strength and, together with the positioning groove block 19, restricts the position of the hook bracket 11, ensuring the positioning of multiple cable conductors 10. The docking block 17 and the docking hole 18 cooperate with each other to ensure the connection between the hook bracket 11 and the cable conductors 10. The hook bracket 11 restricts the multiple cable conductors 10 to ensure the stability of the internal cable conductors 10. The mutual restriction between multiple cable conductors 10 ensures that the position of each cable conductor 10 is precisely fixed, preventing relative displacement, wear or kinking caused by vibration or bending during use. This greatly reduces the risk of short circuits and local insulation wear, and ensures the long-term stability of the electrical connection.

[0027] Specifically, it also includes fiber optic mechanisms, which are arranged in two groups. Both groups of fiber optic mechanisms are located inside the bushing 7. Each group of fiber optic mechanisms includes a fiber optic unit line 12 and a support frame 13. The fiber optic unit line 12 is installed inside the bushing 7, and the support frame 13 is fixedly connected inside the bushing 7. The inner wall of the support frame 13 is wrapped around the outer surface of the fiber optic unit line 12.

[0028] In this embodiment, the fiber optic unit line 12 is used to transmit optical signals. It has the characteristics of high bandwidth and anti-electromagnetic interference. It is often used for communication, sensing or high-frequency data. It works with the support frame 13 to complete the positioning of the fiber optic unit line 12.

[0029] During use, the protective layer 1 provides overall basic protection. The anti-salt spray layer on the surface ensures anti-salt spray performance. The hydrophobic layer 2 makes it difficult for water to adhere and penetrate laterally, actively preventing water penetration and diffusion. The metal mesh 4 shields electromagnetic interference, blocking external electromagnetic interference from entering the cable and preventing electromagnetic radiation leakage from inside the cable. The wear-resistant layer 5 provides additional wear resistance life. When subjected to high pressure, the pressure is transferred to the internal pressure-resistant spring 6. The bending structure of the pressure-resistant spring 6 undergoes elastic deformation, dispersing the concentrated point load into a surface load. The stress is further buffered and homogenized by the elastic filler 15 that wraps it. During operation, the heat generated by the cable conductor 10 is quickly conducted out and dissipated into the environment by the heat-conducting layer 3 through the wrapping filler 14 and bushing 7. The hook bracket 11 is snapped into the positioning slot block 19, and the mutual restraint between multiple cable conductors 10 is completed through the cooperation of the docking block 17 and the docking hole 18. The integrated optical fiber unit line 12 is individually fixed and protected by the support frame 13, transmitting real-time operating data of the photovoltaic string.

[0030] The control method of this invention is to control the device by manually starting and stopping the switch. The wiring diagram of the power element and the supply of power are common knowledge in the field. Since this invention is mainly used to protect mechanical devices, the control method and wiring layout will not be explained in detail.

[0031] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A salt mist resistant photovoltaic system dedicated cable, characterized in that, include: Protective layer (1); The outer protective mechanism is located inside the protective layer (1); The inner protective mechanism is located within the outer protective mechanism; Multiple cable conductors (10) are provided, and all of the multiple cable conductors (10) are installed in the inner protective mechanism; A pressure-resistant mechanism is provided between the outer protection mechanism and the inner protection mechanism. The pressure-resistant mechanism includes a pressure-resistant spring sheet (6) and an elastic filler (15). The pressure-resistant spring sheet (6) is installed between the outer protection mechanism and the inner protection mechanism. The elastic filler (15) is installed between the outer protection mechanism and the inner protection mechanism, and the elastic filler (15) is wrapped around the pressure-resistant spring sheet (6). The positioning mechanism is located within the inner protection mechanism and is connected to multiple cable conductors (10). The positioning mechanism includes a base column component, a docking component, and a hook and loop bracket (11). The base column component is located within the inner protection mechanism. Multiple hook and loop brackets (11) are provided, and multiple hook and loop brackets (11) are provided on the base column component. Multiple docking components are provided, and every two sets of docking components are provided on each hook and loop bracket (11). Each set of docking components is connected to each cable conductor (10).

2. A salt-fog resistant photovoltaic system cable according to claim 1, wherein: The outer protective structure includes a metal mesh (4), a wear-resistant layer (5), a hydrophobic layer (2), and a thermally conductive layer (3). The hydrophobic layer (2) is installed inside the protective layer (1), the thermally conductive layer (3) is installed inside the hydrophobic layer (2), the metal mesh (4) is installed inside the thermally conductive layer (3), and the wear-resistant layer (5) is installed inside the metal mesh (4).

3. A salt-fog resistant photovoltaic system cable as claimed in claim 1, wherein: The inner protective mechanism includes a tension reinforcing rib (8), a support partition (9), a bushing (7), and a wrapping filler (14). The bushing (7) is installed inside the compression spring (6), and the wrapping filler (14) is filled inside the bushing (7). There are two support partitions (9), which are fixedly connected to the two sides inside the bushing (7). There are two tension reinforcing ribs (8), and each tension reinforcing rib (8) is installed inside each support partition (9).

4. A salt-fog resistant photovoltaic system cable as claimed in claim 1, wherein: The base column component includes a tension rib (16) and a positioning groove (19). The tension rib (16) is installed at the center inside the bushing (7). There are multiple positioning grooves (19). The multiple positioning grooves (19) are fixedly connected to the tension rib (16) at equal intervals. Each hook bracket (11) is snapped into each positioning groove (19).

5. A salt-fog resistant photovoltaic system cable as claimed in claim 1, wherein: Each of the docking components includes a docking block (17) and a docking hole (18). The docking block (17) is fixedly connected to the cable conductor (10), and the docking hole (18) is opened on the hook and ring bracket (11) and is snapped onto the docking block (17).

6. A salt-fog resistant photovoltaic system cable as claimed in claim 1, wherein: It also includes fiber optic mechanisms, which are arranged in two groups. Both groups of fiber optic mechanisms are located inside bushings (7). Each group of fiber optic mechanisms includes fiber optic unit lines (12) and support frames (13). The fiber optic unit lines (12) are installed inside bushings (7), and the support frames (13) are fixedly connected inside bushings (7). The inner wall of the support frames (13) is wrapped around the outer surface of the fiber optic unit lines (12).

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