A cable with a wide applicable temperature range

Abstract

A cable with a wide applicable temperature range, belonging to the cable industry, has a structure including a conductor layer, a binding layer, an insulation layer, and a flat sheath layer. The conductor layer is formed by stranding multiple metal wires to form a spiral current-conducting structure. The binding layer wraps around the conductor layer. The insulation layer includes an insulating inner tube wrapped around the binding layer and an insulating outer tube wrapped around the insulating inner tube. The insulation layer in the stranded flat cable is composed of an insulating inner tube and an insulating outer tube. The insulating inner tube and the insulating outer tube have eccentric cavities with their centers offset from each other, so that the wall thickness of the insulation layer is the same as the wall thickness of the single-layer insulation sheath in the prior art, without affecting the thickness of the flat portion of the flat sheath layer. While strengthening the insulation performance, it also has strong tear resistance. A temperature response unit for positioning the binding layer connection is provided on the inner wall of the cavity at the thickest position of the insulating inner tube, which can perform rapid high-temperature response and effectively prevent the cable from being damaged by overheating.

Description

Technical Field

[0001] This invention relates to a cable with a wide applicable temperature range, belonging to the field of cables. Background Technology

[0002] A cable is a device used to transmit electrical energy or signals. It typically consists of multiple insulated conductors covered by an external insulating layer. Its core function is to transmit current or signals through the directional movement of free electrons within the conductors. Cables are widely used in power systems, communication networks, and electrical equipment connections. Flat cables are a type of cable whose biggest advantage is space saving, making them particularly suitable for scenarios requiring flexible cable routing or where space is limited. Flat cables include side-by-side flat cables and stranded flat cables. In side-by-side flat cables, the conductors are arranged side by side and can only be bent in both directions. In stranded flat cables, the conductors are twisted together, allowing for arbitrary bending. However, due to the structural characteristics of the flat sheath, the thickness of the insulation sleeve outside the conductors is limited, requiring only a single layer of insulation. Otherwise, for stranded flat cables of the same specifications, multiple layers of insulation would make the flat end face of the flat sheath too thin, making it prone to cracking under frequent bending. Summary of the Invention

[0003] To address the shortcomings of existing technologies, the purpose of this invention is to provide a cable with a wide applicable temperature range. This addresses the problem that while existing stranded flat cables allow for bending due to the twisted nature of the conductors, the thickness of the insulation sleeve outside the conductors is limited by the structure of the flat sheath. A single layer of insulation is required; otherwise, in stranded flat cables of the same specification, multiple layers of insulation would make the flat end face of the sheath too thin, leading to breakage under frequent bending.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a cable with a wide applicable temperature range, comprising a conductor layer, a binding layer, an insulation layer, and a flat sheath layer. The conductor layer is formed by stranding multiple metal wires to create a spiral current-conducting structure. The binding layer is wrapped around the conductor layer. The insulation layer includes an inner insulating tube wrapped around the binding layer and an outer insulating tube wrapped around the inner insulating tube. The inner insulating tube has a left-biased structure, and the outer insulating tube has a right-biased structure, so that the thickest part of the inner insulating tube is connected to the thinnest part of the outer insulating tube, and vice versa. The inner wall of the cavity at the thickest part of the inner insulating tube is provided with a temperature-responsive unit for positioning the binding layer connection, and the interlayer at the thickest part of the outer insulating tube is provided with a protective unit for protecting the thinnest part of the inner insulating tube. The flat sheath layer is wrapped around the insulation layer, and the flat portions on the left and right sides of the flat sheath layer correspond to the thickest and thinnest parts of the outer insulating tube, respectively.

[0005] Furthermore, in order to reduce current eddy current loss, the spiral current guiding structure has a twisting pitch ratio of 1:12, and the twisting direction is at an angle of 30°-60° with the cable axis.

[0006] Furthermore, in order to achieve rapid high-temperature response, the temperature response unit is composed of shape memory alloy wires, which are distributed in a mesh pattern to change shape to form heat dissipation channels when the ambient temperature exceeds a threshold.

[0007] Furthermore, in order to achieve electromagnetic shielding and protection of the binding layer, the protection unit is arc-shaped and is composed of aluminum foil and tin-plated copper wire mesh. The aluminum foil layer is folded in a sawtooth pattern, forming an interlaced electromagnetic shielding protection structure with the tin-plated copper wire mesh.

[0008] Furthermore, in order to enhance the absorption and reflection of electromagnetic waves, the aluminum foil layer is folded at an angle of 25°–35°.

[0009] Furthermore, to prevent overheating damage to the cable, the shape memory alloy wire has a mesh density of 10–20 meshes / cm², a temperature threshold of 60℃–90℃, and a heat dissipation channel width of 0.3–0.5mm.

[0010] Furthermore, in order to enhance the tensile strength, impact strength and wear resistance of the insulation layer, the inner insulating tube is made of cross-linked polyethylene and its inner wall has a corrugated pattern, while the outer insulating tube is made of polytetrafluoroethylene.

[0011] Furthermore, in order to enhance the positioning effect of the binding layer on the spiral flow guiding structure, the wave crest height of the corrugated pattern on the inner wall of the insulating inner tube cavity is 0.5–1.0 mm, and the wave pitch is 3–5 mm.

[0012] Furthermore, in order to improve mechanical protection performance, a wear-resistant coating or flame-retardant coating is also provided on the outer surface of the flat sheath layer.

[0013] The beneficial effects of this invention are: 1. The insulation layer in stranded flat cables consists of an inner insulating tube and an outer insulating tube. The inner and outer insulating tubes have eccentric cavities with their centers offset from each other, so that the wall thickness of the insulation layer is the same as that of the single-layer insulation sheath in the existing technology. This will not affect the thickness of the flat portion of the flat sheath layer, thus strengthening the insulation performance and providing strong tear resistance.

[0014] Second, a temperature response unit for positioning the binding layer is provided on the inner wall of the tube at the thickest part of the insulating inner tube, which can perform rapid high-temperature response and effectively prevent the cable from being damaged by overheating. Attached Figure Description

[0015] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a schematic diagram of the structure of a cable with a wide applicable temperature range according to the present invention; Figure 2 This is a schematic cross-sectional view of a cable with a wide applicable temperature range according to the present invention. Figure 3 This is a schematic diagram of the cross-sectional structure of the insulating layer; Figure 4 This is a schematic diagram of the cross-sectional structure of the insulating inner tube; Figure 5 This is a schematic diagram of the cross-sectional structure of the insulating outer tube.

[0016] In the diagram: Conductor layer-1, Binding layer-2, Insulating layer-3, Flat sheath layer-4, Insulating inner tube-31, Insulating outer tube-32, Temperature response unit-311, Protection unit-321. Detailed Implementation

[0017] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments. Example 1

[0018] Please see Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 This invention provides a cable technology solution with a wide applicable temperature range: its structure includes a conductor layer 1, a binding layer 2, an insulation layer 3, and a flat sheath layer 4. The conductor layer 1 is formed by stranding multiple metal wires to form a spiral current-conducting structure. The binding layer 2 wraps around the conductor layer 1. The insulation layer 3 includes an inner insulating tube 31 wrapped around the binding layer 2 and an outer insulating tube 32 wrapped around the inner insulating tube 31. The inner insulating tube 31 has a left-biased structure, and the outer insulating tube 32 has a right-biased structure, so that the inner insulating tube 31 is the thickest part of the cable. The position is connected to the thinnest position of the outer insulating tube 32, and the thickest position of the outer insulating tube 32 is connected to the thinnest position of the inner insulating tube 31. The inner wall of the cavity at the thickest position of the inner insulating tube 31 is provided with a temperature response unit 311 for connecting and positioning the binding layer 2. The interlayer at the thickest position of the outer insulating tube 32 is provided with a protection unit 321 for protecting the thinnest position of the inner insulating tube 31. The flat sheath layer 4 is wrapped around the insulating layer 3. The flat portions on the left and right sides of the flat sheath layer 4 correspond to the thickest position and the thinnest position of the outer insulating tube 32, respectively.

[0019] Among them, the binding layer 2 is made of rubber. After the insulating inner tube 31 and the insulating outer tube 32 are combined, the wall thickness of the left and right parts of the double-layer insulation structure formed by the two is the same as the wall thickness of the single-layer insulation sleeve in the prior art. It will not affect the thickness of the flat part of the flat sheath layer 4, and while strengthening the insulation performance, it also has strong tear resistance.

[0020] To reduce eddy current losses, the spiral guide structure has a twisting pitch ratio of 1:12, and the twisting direction forms an angle of 30°-60° with the cable axis, preferably 45°.

[0021] To enable rapid response at high temperatures, the temperature response unit 311 is composed of shape memory alloy wires distributed in a mesh pattern to change shape and form heat dissipation channels when the ambient temperature exceeds a threshold.

[0022] Among them, shape memory alloy wire is an existing technology, a kind of smart material that can "remember" its initial shape. It can automatically restore its original shape after heating, and at the same time has super elasticity and high damping characteristics. It is mainly made of nickel-titanium alloy and achieves its function through the austenitic-martensite phase transformation.

[0023] In order to achieve electromagnetic shielding and protect the binding layer 2, the protection unit 321 is arc-shaped and is composed of aluminum foil and tin-plated copper wire mesh. The aluminum foil layer is folded in a sawtooth shape, forming an interlaced electromagnetic shielding protection structure with the tin-plated copper wire mesh.

[0024] To enhance the absorption and reflection of electromagnetic waves, the aluminum foil layer is folded at an angle of 25°–35°. The folded structure gives the aluminum foil layer better bending performance and fatigue resistance, enabling the cable to maintain shielding integrity even when frequently bent or moved, making it less prone to cracks or breaks and extending the cable's service life.

[0025] To prevent overheating damage to the cable, the shape memory alloy wire has a mesh density of 10–20 meshes / cm², a temperature threshold set at 60℃–90℃, and a heat dissipation channel width of 0.3–0.5mm. When the ambient temperature exceeds the preset threshold of 60℃–90℃, the shape memory alloy undergoes a martensitic phase transformation, and the mesh shrinks to form a heat dissipation channel. This design enables the cable to have intelligent temperature control, automatically activating heat dissipation in high-temperature environments and returning to its original state at low temperatures, thus achieving passive temperature management.

[0026] To enhance the tensile strength, impact strength, and wear resistance of the insulation layer 3, the inner insulation tube 31 is made of cross-linked polyethylene and its inner wall has a corrugated pattern, while the outer insulation tube 32 is made of polytetrafluoroethylene.

[0027] Among them, cross-linked polyethylene material forms a three-dimensional network structure through cross-linking treatment, with a long-term working temperature of up to 90℃, a short-term overload temperature of up to 130℃, and a maximum heat resistance temperature of up to 250℃ during short circuit. Polytetrafluoroethylene has a melting point as high as 327℃, a continuous use temperature of up to 260℃, and maintains stable performance in a wide temperature range of -80℃ to 260℃.

[0028] To complement the enhanced positioning effect of the binding layer 2 on the spiral flow guiding structure, the wave crest height of the corrugated pattern on the inner wall of the insulating inner tube 31 is 0.5–1.0 mm, and the wave pitch is 3–5 mm. Example 2

[0029] For the sake of brevity, the parts that are the same as those in other embodiments will not be described again. The main focus is on the structure that is different from other embodiments of the present invention. In order to improve mechanical protection performance, a wear-resistant coating or flame-retardant coating is also provided on the outer surface of the flat sheath layer 4. It is preferably a flame-retardant coating, specifically CDDT-A type cable fire retardant coating, which conforms to GB28374-2012 standard. The coating is thin, has strong adhesion, and has anti-corrosion function.

[0030] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0031] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A cable with a wide applicable temperature range, characterized in that: Its structure includes a conductor layer (1), which is formed by twisting multiple strands of metal wires to form a spiral flow-guiding structure; A binding layer (2) is wrapped around the conductor layer (1); The insulating layer (3) includes an insulating inner tube (31) wrapped in the binding layer (2) and an insulating outer tube (32) wrapped in the insulating inner tube (31). The cavity of the insulating inner tube (31) is eccentric to the left, and the cavity of the insulating outer tube (32) is eccentric to the right, so that the thickest position of the insulating inner tube (31) is connected to the thinnest position of the insulating outer tube (32), and the thickest position of the insulating outer tube (32) is connected to the thinnest position of the insulating inner tube (31). The inner wall of the cavity at the thickest position of the insulating inner tube (31) is provided with a temperature response unit (311) for connecting and positioning the binding layer (2), and the interlayer at the thickest position of the insulating outer tube (32) is provided with a protection unit (321) for protecting the thinnest position of the insulating inner tube (31). A flat sheath layer (4) is wrapped around the insulating layer (3). The flat parts on the left and right sides of the flat sheath layer (4) correspond to the thickest position and the thinnest position of the insulating outer tube (32), respectively.

2. The cable with a wide applicable temperature range according to claim 1, characterized in that: The spiral guide structure has a twisting pitch ratio of 1:12, and the twisting direction forms an angle of 30°-60° with the cable axis.

3. The cable with a wide applicable temperature range according to claim 1, characterized in that: The temperature response unit (311) is composed of shape memory alloy wires, which are distributed in a mesh pattern to change shape to form heat dissipation channels when the ambient temperature exceeds a threshold.

4. The cable with a wide applicable temperature range according to claim 1, characterized in that: The protection unit (321) is arc-shaped and is composed of aluminum foil and tin-plated copper wire mesh. The aluminum foil layer is folded in a sawtooth shape, forming an interlaced electromagnetic shielding protection structure with the tin-plated copper wire mesh.

5. The cable with a wide applicable temperature range according to claim 4, characterized in that: The aluminum foil layer is folded at an angle of 25°–35°.

6. The cable with a wide applicable temperature range according to claim 3, characterized in that: The shape memory alloy wire has a mesh density of 10–20 meshes / cm², a temperature threshold of 60℃–90℃, and a heat dissipation channel width of 0.3–0.5mm.

7. The cable with a wide applicable temperature range according to claim 1, characterized in that: The inner insulating tube (31) is made of cross-linked polyethylene and its inner wall has a corrugated pattern. The outer insulating tube (32) is made of polytetrafluoroethylene.

8. The cable with a wide applicable temperature range according to claim 7, characterized in that: The wave crest height of the corrugated pattern on the inner wall of the insulating inner tube (31) is 0.5–1.0 mm, and the wave pitch is 3–5 mm.

9. A cable with a wide applicable temperature range according to claim 1, characterized in that: It also includes a wear-resistant coating or a flame-retardant coating disposed on the outer surface of the flat sheath layer (4).

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