A new waterproof, corrosion-resistant and ultraviolet-resistant photovoltaic cable

Abstract

The application discloses a waterproof, corrosion-resistant and ultraviolet-resistant novel photovoltaic cable in the technical field of photovoltaic cables, which comprises, from inside to outside, a coaxially arranged center tensile reinforcing core, a conductor, a semi-conductive watertight layer, an insulating layer, a spiral anti-bending reinforcing layer, a water-blocking buffer layer, a corrosion-resistant inner layer, a metal braided reinforcing layer, an elastic energy-absorbing buffer layer and an ultraviolet-resistant outer sheath. The application forms a three-dimensional waterproof system through the semi-conductive watertight layer and the water-blocking buffer layer, forms a gradient corrosion-resistant barrier through a multi-level structure, realizes long-acting ultraviolet-resistant aging through the synergistic effect of nano-modified materials and structural optimization, and simultaneously improves the tensile, anti-bending, impact-resistant and wear-resistant properties in combination with a multi-level mechanical reinforcing structure, so that the operation stability and service life of the cable in complex and harsh outdoor environments such as deserts, coasts and beaches can be significantly improved, and the use requirement of long-period low-maintenance of photovoltaic power stations can be met.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic cable technology, and in particular to a novel photovoltaic cable that is waterproof, corrosion-resistant, and UV-resistant. Background Technology

[0002] As a key power transmission component connecting components, combiner boxes, and inverters in photovoltaic systems, the reliability, environmental adaptability, and service life of photovoltaic cables directly determine the power generation efficiency and life-cycle benefits of the power station. Photovoltaic power stations are mostly built in open outdoor areas, with some located in coastal mudflats, saline-alkali areas, industrial and mining areas, and plateau regions. The cables are subjected to multiple harsh conditions such as direct sunlight, temperature changes, high humidity, salt spray, and acid and alkali corrosion for a long time, requiring extremely high comprehensive protection performance.

[0003] Existing conventional photovoltaic cables have several technical shortcomings: First, their waterproof and sealing performance is insufficient. The multi-layer extruded structure is only physically bonded between layers, and the microscopic gaps easily lead to radial penetration and axial migration of moisture, causing conductor corrosion and a decline in insulation performance. Existing single-layer water-blocking tapes have poor adhesion and cannot form a complete sealing system, resulting in limited axial water-blocking effect. Second, their corrosion resistance is limited. Ordinary polyolefin sheaths are prone to molecular chain degradation and surface powdering and cracking in salt spray and acid / alkali environments. The intrusion of corrosive media will accelerate the deterioration of the internal structure and shorten the service life. Third, their resistance to ultraviolet aging is insufficient. Existing sheaths mostly rely on organic light stabilizers, and these additives are prone to migration and precipitation. First, the activity decays rapidly under sunlight, making it difficult to support long-term weather resistance requirements. Continuous ultraviolet radiation damages the polymer chains, easily leading to sheath brittleness and becoming a shortcoming in the lifespan of power plants. Second, the functional layers lack synergistic effects. Simple superposition of single functional layers easily increases the cable's outer diameter and reduces flexibility. Furthermore, insufficient interlayer bonding easily leads to delamination, making it difficult to simultaneously improve multi-dimensional performance. Third, the mechanical protection performance is difficult to adapt to complex laying conditions. When laid in complex terrains such as mountains and deserts, cables are easily subjected to dragging, stretching, sand and gravel compression, bending fatigue, etc., leading to sheath damage and internal structural deformation. The existing structure lacks targeted multi-level mechanical reinforcement design, resulting in high laying losses and operational failure rates. Summary of the Invention

[0004] In view of the problems existing in the prior art, the present invention proposes a novel waterproof, corrosion-resistant and UV-resistant photovoltaic cable to solve such problems.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable, comprising, from the inside out, a central tensile reinforcing core, a conductor, a semi-conductive watertight layer, an insulation layer, a spiral anti-bending reinforcing layer, a water-blocking buffer layer, a corrosion-resistant inner layer, a metal braided reinforcing layer, an elastic energy-absorbing buffer layer, and a UV-resistant outer sheath, arranged coaxially from the inside out. The outer surface of the UV-resistant outer sheath is provided with an integrated axial wear-resistant protrusion, and axial micro-stress relief grooves are formed between adjacent wear-resistant protrusions. The semi-conductive watertight layer is composed of a semi-conductive polyolefin matrix and a highly absorbent and expandable resin, and has both electric field homogenization and radial water-blocking functions. The water-blocking buffer layer is longitudinally wrapped with a polyester water-blocking tape coated with hot melt adhesive on both sides, and the interlayer gaps can be eliminated by hot melt bonding. The corrosion-resistant inner layer is a fluoroplastic modified polyolefin composite material. The UV-resistant outer sheath is a nano-composite modified irradiated cross-linked polyolefin material with a built-in multiple UV protection system.

[0006] In a preferred embodiment of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention, an energy storage channel is formed inside the central tensile reinforcing core, the inner side of the energy storage channel is filled with modified asphalt, and multiple sets of reinforcing fibers are evenly distributed on the outer side of the central tensile reinforcing core, with the reinforcing fibers spirally coiled on the outer wall of the central tensile reinforcing core.

[0007] As a preferred embodiment of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention, the conductor is made of multiple strands of tin-plated soft copper wires twisted together, with a tin-plated layer uniformly covering the surface of each copper wire. The semi-conductive watertight layer is uniformly wrapped around the outside of the conductor and is made of a composite blend of a semi-conductive polyolefin matrix and a highly absorbent and expandable resin.

[0008] As a preferred embodiment of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention, the insulation layer is an irradiated cross-linked low-smoke halogen-free flame-retardant polyolefin material, which forms a three-dimensional network cross-linked structure after being irradiated by an electron beam.

[0009] As a preferred embodiment of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention, the spiral anti-bending reinforcement layer is formed by spirally wrapping high-strength polyester fiber tape to form a flexible reinforcement skeleton, and spiral grooves with the same spiral structure are provided between the spirally wrapped polyester fiber tapes.

[0010] As a preferred embodiment of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention, the water-blocking buffer layer is made of polyester water-blocking tape coated with hot melt adhesive on both sides, which is longitudinally wrapped around the outside of the spiral anti-bending reinforcement layer. Multiple sets of axial water-blocking strips are evenly and equally distributed on the outer wall of the water-blocking buffer layer, and an axial micro-guide groove is provided between each two adjacent sets of axial water-blocking strips.

[0011] As a preferred embodiment of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention, the corrosion-resistant inner layer is extruded from a fluoroplastic modified polyolefin composite material, and its outer wall is equally divided with multiple sets of corrugated grooves.

[0012] As a preferred embodiment of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention, wherein: the elastic energy-absorbing buffer layer is a highly elastic modified polyolefin material, which is extruded onto the outside of the metal braided reinforcement layer.

[0013] As a preferred embodiment of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention, the wear-resistant ridges and the UV-resistant outer sheath are integrally extruded and uniformly distributed along the axial direction, and the cross-section is in the shape of a circular arc protrusion.

[0014] As a preferred embodiment of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention, the micro-stress relief groove extends continuously along the axial direction, has a cross-section of a wide and shallow circular arc groove, a smooth bottom without sharp corners, and a groove width that is 3 to 4 times the groove depth.

[0015] The beneficial effects of this invention are as follows: 1. A three-dimensional waterproof system with excellent sealing performance. By combining the radial water-blocking of the semi-conductive watertight layer with the axial water-blocking of the water-blocking buffer layer through hot-melt bonding, and with the gap-filling effect of the elastic energy-absorbing buffer layer, a three-dimensional waterproof structure is formed in all directions. It blocks the radial water seepage path from the inside, eliminates the gap between layers through hot-melt bonding, and completely blocks the axial water seepage channel. The multi-structure synergy achieves full-dimensional isolation of water intrusion, which can effectively adapt to various harsh water environments such as high humidity and rain, direct underground burial, and near-water laying, and avoids the problems of conductor oxidation and insulation failure due to moisture from the root.

[0016] 2. A gradient-coordinated anti-corrosion structure provides outstanding corrosion resistance. It employs a three-tiered corrosion-resistant design: an UV-resistant outer sheath, a metal braided reinforcement layer, and a corrosion-resistant inner layer. Each layer provides protection from the outside in, with progressive reinforcement. The UV-resistant outer sheath serves as the first line of defense against most external corrosive media; the metal braided reinforcement layer forms a dense metal barrier to further block penetration and enhance mechanical protection; the corrosion-resistant inner layer provides the core protection against corrosive media that penetrate the outer layer. This multi-layered synergistic effect significantly improves the cable's tolerance to various corrosive environments such as salt spray, acids, alkalis, and chemical solvents, making it suitable for complex corrosive conditions in coastal areas, industrial zones, and saline-alkali lands.

[0017] 3. A multi-layered UV protection system ensures long-lasting weather resistance. The UV-resistant outer sheath employs a multi-layered UV protection system combining inorganic nanofillers, organic UV absorbers, and free radical scavengers. Through a triple mechanism of physical shielding, energy conversion, and chemical stabilization, it comprehensively resists UV damage to the sheath material. Combined with the mechanical protection of the protective layer by surface wear-resistant ridges, it effectively solves the problems of easy migration, precipitation, and insufficient long-term effectiveness of traditional single organic light stabilizers. It can maintain protective activity for a long time, significantly extending the outdoor service life of the cable, matching or even exceeding the design life cycle of photovoltaic modules, and greatly reducing the operation, maintenance, and replacement costs throughout the entire life cycle of the power station.

[0018] 4. Multi-level mechanical reinforcement system with strong adaptability to working conditions: This invention constructs a multi-level mechanical protection structure from the inside out: a central tensile reinforcement core enhances the overall tensile load-bearing capacity, adapting to large-span and drag-and-drop construction; a spiral anti-bending reinforcement layer disperses bending stress and improves bending fatigue life; a metal braid reinforcement layer strengthens resistance to compression and impact; an elastic energy-absorbing buffer layer absorbs external impact energy; and a UV-resistant outer sheath with wear-resistant ridges reduces friction and wear. The synergistic effect of the multi-layered mechanical structure gives the cable both high strength and high flexibility, enabling it to adapt to laying and operating conditions in complex terrains such as mountains, deserts, and tidal flats, significantly reducing the mechanical damage failure rate.

[0019] 5. Overall cross-linked structure with excellent comprehensive performance: The insulation layer and the UV-resistant outer sheath of this invention are both treated with irradiation cross-linking process to form a stable three-dimensional network molecular structure, which greatly improves the material's high temperature resistance, low temperature resistance, wear resistance and crack resistance. The cable can operate stably in a wide temperature range environment, and the short circuit withstand capability is significantly improved. At the same time, each functional layer is tightly bonded through process optimization to avoid the problem of interlayer delamination during long-term operation, and to ensure the long-term stability and integrity of the protective performance. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein:

[0021] Figure 1 This is a schematic diagram of the overall structure of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention.

[0022] Figure 2 This is a schematic diagram of the cross-section of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention.

[0023] Figure 3This is a schematic diagram of the structure of the spiral anti-bending reinforcement layer of the novel photovoltaic cable that is waterproof, corrosion-resistant, and UV-resistant according to the present invention.

[0024] Figure 4 This is a schematic diagram of the structure of the water-blocking buffer layer of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention.

[0025] Figure 5 This is a schematic diagram of the corrosion-resistant inner layer of the novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable of the present invention.

[0026] Figure 6 This is a schematic diagram of the structure of the UV-resistant outer sheath of the novel photovoltaic cable of the present invention, which is waterproof, corrosion-resistant, and UV-resistant.

[0027] Reference numerals: 1. Central tensile reinforcing core; 2. Conductor; 3. Semi-conductive watertight layer; 4. Insulating layer; 5. Spiral anti-bending reinforcing layer; 51. Spiral groove; 6. Water-blocking buffer layer; 61. Water-blocking strip; 62. Axial micro-guide groove; 7. Corrosion-resistant inner layer; 71. Corrugated groove; 8. Metal braided reinforcing layer; 9. Elastic energy-absorbing buffer layer; 10. UV-resistant outer sheath; 11. Wear-resistant ridge; 12. Micro-stress relief groove; 13. Energy storage pipe; 14. Reinforcing fiber. Detailed Implementation

[0028] To make the above-mentioned objectives, features and advantages of the present invention more readily understood, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0029] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0030] Reference Figures 1 to 6This invention provides a novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable, comprising, from the inside out, a central tensile reinforcing core 1, a conductor 2, a semi-conductive watertight layer 3, an insulation layer 4, a spiral anti-bending reinforcing layer 5, a water-blocking buffer layer 6, a corrosion-resistant inner layer 7, a metal braiding reinforcing layer 8, an elastic energy-absorbing buffer layer 9, and a UV-resistant outer sheath 10. The outer surface of the UV-resistant outer sheath 10 has integrated axial wear-resistant protrusions 11, and axial micro-stress relief grooves 12 are formed between adjacent wear-resistant protrusions 11. The semi-conductive watertight layer 3 is composed of a semi-conductive polyolefin matrix and a highly absorbent and expandable resin, providing both electric field homogenization and radial water-blocking functions. The water-blocking buffer layer 6 is longitudinally wrapped with polyester water-blocking tape coated with hot-melt adhesive on both sides, which can eliminate interlayer gaps through hot-melt bonding. The corrosion-resistant inner layer 7 is a fluoroplastic-modified polyolefin composite material. The UV-resistant outer sheath 10 is a nano-composite modified irradiated cross-linked polyolefin material with a built-in multi-layer UV protection system.

[0031] Reference Figure 1 The central tensile reinforcing core 1 has an energy storage pipe 13 inside, and the inner side of the energy storage pipe 13 is filled with modified asphalt. Multiple sets of reinforcing fibers 14 are evenly distributed on the outer side of the central tensile reinforcing core 1, and the reinforcing fibers 14 are spirally coiled on the outer wall of the central tensile reinforcing core 1. When the conductor 2 heats up due to current transmission, the heat will be transferred to the energy storage pipe 13. The modified asphalt inside can absorb the heat, thereby cooling the cable and preventing it from overheating and being damaged.

[0032] During use, the photovoltaic equipment can generate electricity when there is sufficient sunlight during the day, but it cannot generate electricity at night when there is no sunlight. This causes conductor 2 to transmit current and generate heat during the day, but stop transmitting current and generating heat at night, resulting in a large temperature difference between day and night. This can easily cause thermal expansion and contraction. At this time, the modified asphalt located in the energy storage pipe 13 can absorb heat during the day and release it at night, which can keep conductor 2 warm and heat it, thereby balancing the temperature difference between day and night and reducing the degree of deformation caused by thermal expansion and contraction of conductor 2.

[0033] Reference Figure 2 Furthermore, the reinforcing fiber 14, together with the central tensile reinforcing core 1, is located at the very center of the cable. Both are made of multiple strands of high-strength aramid fiber bundles twisted together, possessing high tensile strength, low elongation, and excellent aging resistance. The copper wire of the conductor 2 is regularly stranded around the tensile core, which can significantly improve the overall tensile load-bearing capacity of the cable. It is suitable for long-span laying in mountainous areas, high-altitude suspension installation, and dragging construction, etc., to prevent the conductor 2 from being deformed or broken by tension. At the same time, it can buffer the internal stress of the conductor 2 and improve the bending fatigue resistance.

[0034] Reference Figure 2Conductor 2 is made of multiple strands of tin-plated soft copper wires twisted together. The surface of each copper wire is uniformly covered with a tin-plated layer. The copper wires of conductor 2 are twisted around the tensile core in a regular manner, which can significantly improve the overall tensile load-bearing capacity of the cable. It is suitable for long-span laying in mountainous areas, high-altitude suspension installation and dragging construction, etc., to prevent conductor 2 from being deformed or broken by tension. At the same time, it can buffer the internal stress of conductor 2 and improve the bending fatigue resistance.

[0035] Reference Figure 1 Furthermore, a semi-conductive watertight layer 3 is uniformly coated on the outside of the conductor 2. It is made of a composite blend of a semi-conductive polyolefin matrix and a highly absorbent and expandable resin. This layer has the dual functions of conductor shielding and radial water blocking: the semi-conductive material can uniformly distribute the electric field on the surface of the conductor 2, eliminate the electric field concentration caused by burrs and stranding gaps on the surface of the conductor 2, avoid insulation degradation caused by partial discharge, and improve the long-term electrical operation stability of the cable; the highly absorbent and expandable resin is uniformly dispersed in the matrix. When a trace amount of water seeps into this layer, the water-absorbing resin can quickly absorb the water and expand in volume, filling the micropores and gaps in the layer to form a dense water-blocking barrier, blocking the path of water to further penetrate inward, and achieving a highly efficient radial waterproofing effect.

[0036] Reference Figure 1 The insulation layer 4 is made of irradiated cross-linked low-smoke halogen-free flame-retardant polyolefin material. After electron beam irradiation, it forms a three-dimensional network cross-linked structure. The irradiation cross-linking process can significantly improve the high temperature resistance, anti-aging performance and mechanical strength of the insulation material, enabling the cable to operate stably in a wide temperature range and greatly improving the short-circuit withstand capability. At the same time, the material maintains excellent electrical insulation performance and low-smoke halogen-free flame-retardant characteristics. It produces low smoke and releases no toxic hydrogen halide gas during combustion, which meets the fire safety and environmental protection requirements of photovoltaic power stations.

[0037] Reference Figure 3 The spiral anti-bending reinforcement layer 5 is made of high-strength polyester fiber tape spirally wrapped to form a flexible reinforcement skeleton. Spiral grooves 51 with the same spiral structure are set between the spirally wrapped polyester fiber tapes. By forming a continuous flexible reinforcement skeleton, the spiral anti-bending reinforcement layer 5 can disperse bending stress when the cable is repeatedly bent, limit the deformation range of the insulation layer 4, avoid insulation cracking and interlayer delamination caused by long-term bending, significantly improve the bending fatigue life of the cable, and adapt to the repeated stress caused by multiple bends during laying and temperature difference deformation during operation. The spiral grooves 51 provide room for the spiral anti-bending reinforcement layer 5 during bending deformation.

[0038] Reference Figure 4The water-blocking buffer layer 6 is made of polyester water-blocking tape coated with hot melt adhesive on both sides, which is longitudinally wrapped around the outside of the spiral anti-bending reinforcement layer 5. Multiple sets of axial water-blocking strips 61 are evenly distributed on the outer wall of the water-blocking buffer layer 6. An axial micro-guide groove 62 is provided between each two adjacent sets of axial water-blocking strips 61. The axial micro-guide groove 62 provides clearance space for the axial water-blocking strips 61 to absorb a small amount of water and expand, so that the axial water-blocking strips 61 expand evenly and avoid local bulging deformation that affects the structural stability.

[0039] Reference Figure 5 The corrosion-resistant inner layer 7 is extruded from fluoroplastic modified polyolefin composite material. Its outer wall is equally divided with multiple sets of corrugated grooves 71. When subjected to radial compression and trampling loads, the corrugated grooves 71 of the corrugated structure can buffer the pressure through elastic deformation, improve the cable's anti-flattening performance, increase the layer surface area, disperse environmental stress, and improve the resistance to environmental stress cracking.

[0040] Reference Figure 1 Furthermore, the metal braided reinforcement layer 8 is made of stainless steel wires cross-woven and wrapped around the outside of the corrosion-resistant inner layer 7. Stainless steel itself has excellent corrosion resistance. The mesh metal structure formed by the braid can significantly improve the overall tensile strength, extrusion resistance and impact resistance of the cable, withstand dragging and stretching during laying and installation and external impact in the outdoor environment, and protect the internal core structure. On the other hand, it can form a dense metal barrier layer, further preventing corrosive media from penetrating inward, forming a synergistic anti-corrosion effect with the corrosion-resistant inner layer 7. In addition, the metal braided layer also has an electromagnetic shielding function, which can reduce the impact of external electromagnetic interference on the power transmission and signal acquisition of the photovoltaic system and improve the stability of system operation.

[0041] Reference Figure 1 The elastic energy-absorbing buffer layer 9 is made of highly elastic modified polyolefin material and is extruded onto the outside of the metal braided reinforcement layer 8. Its interior is covered with a honeycomb structure. This layer has good elastic deformation capability and compression recovery performance. When the cable is subjected to external extrusion or impact load, it can absorb energy through elastic deformation, buffer the impact of external force on the internal core wire and the metal braided reinforcement layer 8, and avoid damage to the internal structure due to pressure deformation. At the same time, it can fill the surface gaps of the metal braided reinforcement layer 8, making the extrusion interface of the UV-resistant outer sheath 10 smoother, improving the interlayer bonding force, ensuring the overall structural density and stability, and further blocking the interlayer water seepage path, thus helping to improve waterproof performance.

[0042] Reference Figure 1 and Figure 6Furthermore, the UV-resistant outer sheath 10 is extruded from a nano-composite modified irradiated cross-linked polyolefin material. After irradiation cross-linking treatment, a stable cross-linked network structure is formed. The sheath material constructs a multi-layered synergistic UV protection system: inorganic nano-functional fillers can block most UV rays from entering the material matrix through physical absorption and scattering, reducing the direct damage of UV rays to the polymer chains; organic UV absorbers can convert high-energy UV rays that penetrate the surface into harmless heat energy, reducing the destructive energy of UV rays; hindered amine light stabilizers can capture active free radicals generated during photoaging, interrupting the degradation chain reaction of polymer chains and inhibiting material aging and deterioration. The three types of protective components work synergistically to form gradient protection from the surface to the interior, significantly improving the long-term UV aging resistance of the sheath. At the same time, the UV-resistant outer sheath 10 material also has excellent wear resistance, scratch resistance, and environmental stress cracking resistance, and can adapt to complex outdoor mechanical friction and environmental stress.

[0043] Reference Figure 6 The wear-resistant ridges 11 and the UV-resistant outer sheath 10 are integrally extruded and evenly distributed along the axial direction. The cross-section is arc-shaped and raised. During the laying and installation process, the wear-resistant ridges 11 preferentially contact the ground and the pipe wall, reducing the friction area of ​​the sheath body and significantly reducing the wear of the UV-resistant outer sheath 10, thus preventing the loss of surface UV-resistant functional components due to friction. At the same time, the raised structure can improve the scratch resistance and puncture resistance, effectively resisting the scratches of sand and sharp objects on the outer sheath, and ensuring the structural integrity and long-term protective effect of the UV-resistant outer sheath 10.

[0044] Reference Figure 6 The micro-stress relief groove 12 extends continuously along the axial direction, with a cross-section of a wide and shallow circular arc groove. The bottom of the groove is smooth and without sharp corners. The micro-stress relief groove 12 is opened on the outer surface of the sheath between two adjacent wear-resistant protrusions 11, and extends continuously along the axial direction of the cable. The number of grooves corresponds one-to-one with the wear-resistant protrusions and is evenly distributed in the circumferential direction. The groove width is 3 to 4 times the groove depth, which makes it a wide and shallow structure. When the cable undergoes thermal expansion and contraction deformation due to the temperature difference between day and night, or bending deformation during laying and operation, the micro-stress relief groove 12 can absorb the stress accumulated inside the sheath through its own small elastic deformation, avoiding stress concentration on the sheath surface and causing micro-cracks. From the structural level, it significantly improves the cable's resistance to environmental stress cracking and extends the service life of the outer sheath.

[0045] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable, comprising, from the inside out, a central tensile reinforcing core (1), a conductor (2), a semi-conductive watertight layer (3), an insulation layer (4), a spiral anti-bending reinforcing layer (5), a water-blocking buffer layer (6), a corrosion-resistant inner layer (7), a metal braided reinforcing layer (8), an elastic energy-absorbing buffer layer (9), and a UV-resistant outer sheath (10), characterized in that: The outer surface of the UV-resistant outer sheath (10) is provided with an integrated axial wear-resistant ridge (11), and an axial micro-stress relief groove (12) is provided between adjacent wear-resistant ridges (11). The semi-conductive watertight layer (3) is composed of a semi-conductive polyolefin matrix and a high water-absorbing and swelling resin, which has both electric field homogenization and radial water-blocking functions. The water-blocking buffer layer (6) is made of polyester water-blocking tape coated with hot melt adhesive on both sides, which can eliminate the interlayer gap through hot melt bonding. The corrosion-resistant inner layer (7) is a fluoroplastic modified polyolefin composite material. The UV-resistant outer sheath (10) is a nano-composite modified irradiated cross-linked polyolefin material with a built-in multi-layer UV protection system.

2. The novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable according to claim 1, characterized in that: The energy storage pipe (13) is opened inside the central tensile reinforcing core (1). The inner side of the energy storage pipe (13) is filled with modified asphalt. Multiple sets of reinforcing fibers (14) are evenly arranged on the outer side of the central tensile reinforcing core (1), and the reinforcing fibers (14) are spirally coiled on the outer wall of the central tensile reinforcing core (1).

3. The novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable according to claim 1, characterized in that: The conductor (2) is made of multiple strands of tin-plated soft copper wire twisted together. The surface of each copper wire is uniformly covered with a tin-plated layer. The semi-conductive watertight layer (3) is uniformly wrapped around the outside of the conductor (2) and is made of a composite blend of a semi-conductive polyolefin matrix and a high water-absorbing and swelling resin.

4. The novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable according to claim 1, characterized in that: The insulating layer (4) is an irradiated cross-linked low-smoke halogen-free flame-retardant polyolefin material, which forms a three-dimensional network cross-linked structure after being irradiated by an electron beam.

5. The novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable according to claim 1, characterized in that: The spiral anti-bending reinforcement layer (5) is made of high-strength polyester fiber strips spirally wrapped to form a flexible reinforcement skeleton. Spiral grooves (51) with the same spiral structure are provided between the spirally wrapped polyester fiber strips.

6. The novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable according to claim 1, characterized in that: The water-blocking buffer layer (6) is made of polyester water-blocking tape coated with hot melt adhesive on both sides, which is longitudinally wrapped around the outside of the spiral anti-bending reinforcement layer (5). Multiple sets of axial water-blocking strips (61) are evenly distributed on the outer wall of the water-blocking buffer layer (6), and an axial micro-guide groove (62) is provided between each two adjacent sets of axial water-blocking strips (61).

7. The novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable according to claim 1, characterized in that: The corrosion-resistant inner layer (7) is extruded from fluoroplastic modified polyolefin composite material, and its outer wall is equally divided with multiple sets of corrugated grooves (71).

8. The novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable according to claim 1, characterized in that: The elastic energy-absorbing buffer layer (9) is a highly elastic modified polyolefin material, which is extruded onto the outside of the metal braided reinforcement layer (8).

9. The novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable according to claim 1, characterized in that: The wear-resistant ridge (11) and the UV-resistant outer sheath (10) are integrally extruded and uniformly distributed along the axial direction, with a circular arc protrusion in the cross section.

10. The novel waterproof, corrosion-resistant, and UV-resistant photovoltaic cable according to claim 1, characterized in that: The micro-stress relief groove (12) extends continuously along the axial direction, with a cross-section of a wide and shallow circular arc groove. The bottom of the groove is smooth and without sharp corners, and the width of the groove is 3 to 4 times the depth of the groove.

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