Highly bend-resistant composite conductor cable and electrical device

Abstract

The application provides a high-bending-resistant composite conductor cable and an electric device. The cable comprises a composite conductor and an insulation layer covering the outer side of the composite conductor. The composite conductor comprises aramid reinforced fibers, a plurality of tinned copper wires twisted and wound on the outer side of the aramid reinforced fibers, and a copper foil wire wound on the outer side of the plurality of tinned copper wires. In the cross section of the composite conductor, the aramid reinforced fibers are located in the central region, the plurality of tinned copper wires are distributed along the circumference of the aramid reinforced fibers and form a copper wire twisted layer around the aramid reinforced fibers, and the copper foil wire is located on the radial outer side of the copper wire twisted layer and is spirally wound on the outer periphery of the copper wire twisted layer in the axial direction of the composite conductor. The aramid reinforced fibers provide mechanical support and bending resistance, the tinned copper wires provide stable conductive paths, and the copper foil wire assists conduction and adapts to bending deformation, so that the composite conductor has good conductivity, structural stability and bending resistance, thereby improving the service life of the cable in a dynamic use environment.

Description

Technical Field

[0001] This application belongs to the field of wire and cable technology, and in particular relates to a high-bending-resistant composite conductor cable and an electrical device. Background Technology

[0002] With the development of electrical and automation equipment, cables are widely used in power transmission and electrical connections. In some environments, cables need to undergo bending, twisting, and other deformations as the equipment moves, especially in applications with limited space or continuous movement, where cables may be subjected to repeated bending over a long period of time.

[0003] Existing cables typically consist of a conductor and an insulation layer covering the conductor. The conductor deforms during cable bending. When a cable is subjected to repeated bending over a long period, continuous mechanical stress and fatigue accumulation may occur inside the conductor, affecting its structural stability and service life. Simultaneously, the conductor's structural form and the fit between its components also influence the cable's flexibility, conductivity, and bending resistance. Therefore, improving the reliability and service life of cables under dynamic operating environments such as repeated bending, while still meeting power transmission requirements, remains a key issue in this field.

[0004] It should be noted that the above content is not necessarily prior art, nor is it intended to limit the scope of patent protection of this application. Summary of the Invention

[0005] This application provides a high-bend-resistant composite conductor cable and an electrical device to solve or alleviate one or more technical problems in the prior art.

[0006] The first aspect of this application provides a high-bend-resistant composite conductor cable, including a composite conductor and an insulating layer covering the outside of the composite conductor; The composite conductor includes: Aramid reinforced fiber; Multiple tin-plated copper wires are twisted and wound around the outside of the aramid reinforcing fiber; Copper foil wire is wound around the outside of multiple tin-plated copper wires; In the cross-section of the composite conductor, the aramid reinforcing fiber is located in the central region, and multiple tin-plated copper wires are distributed circumferentially along the aramid reinforcing fiber and surround the aramid reinforcing fiber to form a copper wire stranded layer. The copper foil wire is located radially outside the copper wire stranded layer and spirally wound around the outer periphery of the copper wire stranded layer along the axial direction of the composite conductor.

[0007] Optionally, the diameter of the tin-plated copper wire is 0.05±0.005mm, and the tin-plated copper wire includes an inner copper layer and an outer tin layer, the thickness of which is 0.4~0.8μm.

[0008] Optionally, the number of the plurality of tin-plated copper wires is 165.

[0009] Optionally, the twist pitch of the tin-plated copper wire is 3.5~8mm.

[0010] Optionally, the thickness of the copper foil wire is 0.02~0.03mm.

[0011] Optionally, the aramid reinforced fiber has a tensile strength of 3.0~4.5GPa, an elongation at break of 2.5%~3.5%, an initial modulus of not less than 80GPa, and a heat shrinkage rate of not more than 1.5% at 150℃.

[0012] Optionally, the fineness of the aramid reinforced fiber is 250D, and the diameter of the single filament of the aramid reinforced fiber is 9~11μm.

[0013] Optionally, the composite conductor further includes a nonwoven fabric spirally wound around the outside of the plurality of tin-plated copper wires.

[0014] Optionally, in the cross-section of the composite conductor, the ratio of the cross-sectional areas of the aramid reinforcing fiber, the tin-plated copper wire, and the copper foil wire is 15:72:13.

[0015] A second aspect of this application provides an electrical device comprising a high-bending-resistance composite conductor cable as described in any one of the claims.

[0016] The embodiments of this application employing the above-described technical solution may have the following advantages: The aramid reinforcing fiber in the central region of the composite conductor in this application can improve the mechanical support and bending resistance of the composite conductor. The stranded tinned copper wire can provide a stable conductive path and improve the flexibility of the conductor. The spirally wound copper foil wire can carry current together with the tinned copper wire and adapt to the deformation during the bending process of the conductor. Thus, the composite conductor has good structural stability and bending resistance during repeated bending, while also taking into account conductivity, thereby improving the reliability and service life of the cable in dynamic operating environments.

[0017] The above overview is for illustrative purposes only and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features of this application will become readily apparent from the accompanying drawings and the following detailed description. Attached Figure Description

[0018] In the accompanying drawings, unless otherwise specified, the same reference numerals throughout the various drawings denote the same or similar parts or elements. These drawings are not necessarily drawn to scale. It should be understood that these drawings depict only some embodiments disclosed in this application and should not be construed as limiting the scope of this application.

[0019] Figure 1 This is a schematic diagram of the cross-sectional structure of a high-bending-resistance composite conductor cable provided in an embodiment of this application.

[0020] Explanation of reference numerals in the attached figures: Aramid reinforcing fiber 10; tin-plated copper wire 20; copper foil wire 30; insulation layer 40. Detailed Implementation

[0021] The embodiments of this application are described in detail below, examples of which are illustrated in the accompanying drawings. In the drawings, for clarity, the dimensions of layers, regions, elements, and their relative dimensions may be exaggerated. The same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0022] It should be understood that when an element or layer is referred to as "on," "adjacent to," "connected to," or "coupled to" other elements or layers, it may be directly on, adjacent to, connected to, or coupled to other elements or layers, or there may be intervening elements or layers. Conversely, when an element is referred to as "directly on," "directly adjacent to," "directly connected to," or "directly coupled to" other elements or layers, there are no intervening elements or layers. It should be understood that although the terms first, second, third, etc., may be used to describe various elements, components, areas, layers, and / or portions, these elements, components, areas, layers, and / or portions should not be limited by these terms. These terms are only used to distinguish one element, component, area, layer, or portion from another element, component, area, layer, or portion. Therefore, without departing from the teachings of this application, the first element, component, area, layer, or portion discussed below may be referred to as a second element, component, area, layer, or portion. And the discussion of a second element, component, area, layer, or portion does not imply that the first element, component, area, layer, or portion necessarily exists in this application.

[0023] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0024] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0025] In this application, when numerical intervals (i.e., numerical ranges) are involved, unless otherwise specified, the distribution of selectable numerical values ​​within the numerical interval is considered continuous, and includes the two endpoints of the numerical interval (i.e., the minimum and maximum values), as well as every numerical value between these two endpoints. Unless otherwise specified, when a numerical interval refers only to integers within that numerical interval, it includes the two endpoint integers of the numerical range, as well as every integer between the two endpoints, which is equivalent to directly listing every integer. When multiple numerical ranges are provided to describe features or characteristics, these numerical ranges can be merged. In other words, unless otherwise specified, the numerical ranges disclosed in this application should be understood to include any and all subranges included therein. The "numerical value" in the numerical interval can be any quantitative value, such as a number, percentage, ratio, etc. The term "numerical interval" can be broadly included to include percentage intervals, ratio intervals, proportion intervals, etc.

[0026] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. It should be understood that these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein.

[0027] Please see Figure 1 This application provides a high-bend-resistance composite conductor cable, which includes a composite conductor and an insulation layer. The details are as follows: The composite conductor includes aramid reinforcing fiber 10, multiple tin-plated copper wires 20 and copper foil wires 30, wherein the multiple tin-plated copper wires 20 are twisted and wound around the outside of the aramid reinforcing fiber 10, and the copper foil wires 30 are wound around the outside of the multiple tin-plated copper wires 20. On the cross-section of the composite conductor, the aramid reinforcing fiber 10 is located in the central region, and multiple tin-plated copper wires 20 are distributed circumferentially along the aramid reinforcing fiber 10 and surround the aramid reinforcing fiber 10 to form a copper wire stranded layer. The copper foil wire 30 is located radially outside the copper wire stranded layer and spirally wound around the outer periphery of the copper wire stranded layer along the axial direction of the composite conductor.

[0028] The composite conductor has a composite structure in the radial direction consisting of aramid reinforcing fibers 10, a copper wire stranded layer, and copper foil filaments 30 arranged sequentially from the inside out. The aramid reinforcing fibers 10 are located in the central region of the composite conductor. Multiple tin-plated copper wires 20 are arranged around the aramid reinforcing fibers 10 to form a surrounding structure. The copper foil filaments 30 are further disposed on the outer periphery of the copper wire stranded layer, thereby forming a composite conductor structure with clearly defined radial layers.

[0029] Since the aramid reinforcing fiber 10 is located in the central region, and multiple tin-plated copper wires 20 are twisted around the aramid reinforcing fiber 10, when the composite conductor is bent, the tin-plated copper wires 20 located at different circumferential positions can generate corresponding bending deformations respectively; at the same time, the copper foil wires 30 located on the outer periphery are spirally wound around the copper wire stranded layer, so that the copper foil wires 30 can extend along the axial direction of the composite conductor and form a composite outer peripheral structure with the copper wire stranded layer.

[0030] Aramid reinforcing fiber 10 can improve the mechanical support and bending resistance of the composite conductor. The stranded tinned copper wire 20 can provide a stable conductive path and improve the flexibility of the conductor. The spirally wound copper foil wire 30 can carry current together with the tinned copper wire 20 and adapt to the deformation during the bending process of the conductor. Thus, the composite conductor has good structural stability and bending resistance during repeated bending, while also taking into account conductivity, thereby improving the reliability and service life of the cable in dynamic operating environments.

[0031] In an optional embodiment, the tin-plated copper wire 20 has a diameter of 0.05±0.005mm, and the tin-plated copper wire 20 includes an inner copper layer and an outer tin layer, the thickness of which is 0.4μm~0.8μm.

[0032] Multiple tin-plated copper wires 20 are distributed circumferentially along the aramid reinforcing fiber 10 and twisted together to form a copper wire stranded layer. In one specific embodiment, the number of tin-plated copper wires 20 is 165, thereby forming the copper wire stranded layer together by multiple ultra-fine tin-plated copper wires 20.

[0033] The inner copper layer of the tin-plated copper wire 20 serves as the conductive body, forming the conductive path of the composite conductor. The outer tin layer covers the outside of the inner copper layer to form the surface plating of the tin-plated copper wire 20. The thickness of the outer tin layer is controlled between 0.4 μm and 0.8 μm, so that the tin-plated copper wire 20 maintains a small single wire size while having a corresponding surface plating. The outer tin layer can be formed by hot-dip tin plating, and the outer periphery of the inner copper layer is covered by the outer tin layer.

[0034] Because the tin-plated copper wire 20 adopts an ultra-fine monofilament structure of about 0.05mm, compared with using a thicker single copper wire to form a conductor, multiple tin-plated copper wires 20 can disperse the deformation of the composite conductor during bending to different copper wires. Specifically, when the composite conductor is subjected to bending or reciprocating swaying, the bending deformation borne by the tin-plated copper wires 20 at different circumferential positions is dispersed, thereby reducing stress concentration in local areas of a single copper wire and reducing wire breakage caused by repeated bending.

[0035] Meanwhile, the tin-plated copper wire 20 has a small single-wire diameter, which allows it to adapt to the stranded structure of the composite conductor and to produce corresponding deformation when the composite conductor is bent or twisted. By stranding multiple ultrafine tin-plated copper wires 20 together on the outside of the aramid reinforcing fiber 10, the conductor can have good bending adaptability while maintaining its conductivity.

[0036] The outer tin layer can also form a surface protection for the inner copper layer, reducing the direct exposure of the inner copper layer to the external environment and improving the oxidation resistance of the tin-plated copper wire 20; at the same time, the tin plating layer can maintain the solderability of the tin-plated copper wire 20 to meet the needs of subsequent connection and processing of the composite conductor.

[0037] In an optional embodiment, the pitch of the tin-plated copper wire 20 is 3.5~8mm.

[0038] In this embodiment, multiple tin-plated copper wires 20 are precisely stranded around the aramid reinforcing fiber 10, and the strand pitch is the distance between adjacent stranding cycles along the axial direction of the composite conductor. By controlling the strand pitch of the tin-plated copper wires 20 to 3.5mm~8mm, the multiple tin-plated copper wires 20 have an appropriate stranding angle while stranding around the aramid reinforcing fiber 10.

[0039] When the composite conductor is bent, twisted, or oscillating, the tin-plated copper wire 20 with the above-mentioned pitch can generate corresponding displacement with the deformation of the composite conductor, so that each tin-plated copper wire 20 can slip slightly, thereby dispersing the bending stress on the composite conductor to multiple tin-plated copper wires 20, reducing stress concentration in local areas, and reducing fatigue damage to the tin-plated copper wires 20 caused by repeated bending.

[0040] By controlling the strand pitch within the aforementioned range, the multiple tin-plated copper wires 20 can be kept in a relatively tight stranded state, reducing the risk of loosening, bulging, or displacement of the tin-plated copper wires 20 within the composite conductor, thus giving the copper wire stranded layer a more stable structure. It should be noted that if the strand pitch of the tin-plated copper wires 20 is less than 3.5 mm, it may cause excessive torsional deformation of the tin-plated copper wires 20, resulting in foil detachment and cracking, affecting the conductor's performance.

[0041] In a preferred embodiment, the strand pitch of the tin-plated copper wire 20 is preferably 4.0 mm to 5.0 mm to achieve a better balance between the flexibility of the composite conductor and the structural stability of the copper wire stranding layer.

[0042] In an optional embodiment, the copper foil wire 30 has a thickness of 0.02~0.03mm. In this embodiment, the copper foil wire 30 adopts a thin strip structure. Compared with a circular cross-section copper wire, the copper foil wire 30 can adapt to the bending state of the composite conductor through its own deformation when it bends with the composite conductor, and can generate corresponding slippage during the bending process, thereby reducing the local stress on the copper foil wire 30 during repeated bending.

[0043] The copper foil wire 30 is spirally wound around the outer periphery of the copper wire stranded layer, so that the copper foil wire 30 has a continuous winding path extending along the axial direction of the composite conductor. When the composite conductor is bent or swayed, the copper foil wire 30 can undergo corresponding deformation along its spiral winding path to adapt to the overall bending of the composite conductor, thereby improving the conductivity continuity of the composite conductor under repeated bending conditions.

[0044] Furthermore, the copper foil wire 30 can be a micro-tin-plated copper foil wire 30, and the finished outer diameter of the copper foil wire 30 can be 0.07mm~0.09mm. The copper foil wire 30 can include a fiber substrate and a copper foil wound around the outside of the fiber substrate, and the copper foil is wound around the fiber substrate in a spiral overlapping manner.

[0045] By placing the copper foil wire 30 on the outside of the copper wire stranded layer and adopting a spiral winding structure, the copper foil wire 30 and the copper wire stranded layer form a radial outer layer composite relationship. During the repeated bending and swaying of the composite conductor, the copper foil wire 30 can adapt to the deformation of the composite conductor through its thin strip structure and spiral winding structure, thereby reducing the fatigue damage caused by repeated bending to the copper foil wire 30.

[0046] In an optional embodiment, the aramid reinforcing fiber 10 has a tensile strength of 3.0~4.5GPa, an elongation at break of 2.5%~3.5%, an initial modulus of not less than 80GPa, and a heat shrinkage rate of not more than 1.5% at 150°C.

[0047] The aramid reinforcing fiber 10 serves as a stable central reinforcing structure in the composite conductor. When the composite conductor is subjected to tension, bending, and repeated oscillation, the aramid reinforcing fiber 10 can withstand the corresponding mechanical load, thereby reducing the direct mechanical load on the tin-plated copper wire 20 and preventing copper wire breakage. Simultaneously, the aramid reinforcing fiber 10 has a low thermal shrinkage rate, which reduces the impact of its own dimensional changes on the overall structure of the composite conductor when the composite conductor is subjected to temperature changes or is in a high-temperature environment, maintaining the structural stability between the aramid reinforcing fiber 10 and the surrounding tin-plated copper wire 20 and copper foil wire 30.

[0048] Furthermore, the aramid reinforcing fiber 10 has a fineness of 250D and a single filament diameter of 9-11 μm. Controlling the single filament diameter to 9-11 μm gives the aramid reinforcing fiber 10 a finer single-filament structure, allowing it to be arranged in the central region of the composite conductor in the form of fiber bundles. The finer single filaments give the aramid reinforcing fiber 10 good overall flexibility, enabling it to adapt to the deformation generated during bending and oscillation of the composite conductor. Simultaneously, the 250D fineness provides an appropriate amount of fiber for the central reinforcing structure, allowing the aramid reinforcing fiber 10 to form a continuous reinforcing skeleton within the composite conductor.

[0049] In an alternative embodiment, the composite conductor further includes a nonwoven fabric spirally wound around the outside of the plurality of tin-plated copper wires 20.

[0050] The nonwoven fabric covers the outside of the copper wire stranded layer formed by multiple tin-plated copper wires 20, thereby constraining the tin-plated copper wires 20 and maintaining a relatively stable stranded state. The nonwoven fabric is arranged in a spiral winding manner, which can cover and limit the internal conductor without excessive compression of the composite conductor, reducing the loosening, displacement, or localized protrusion of the tin-plated copper wires 20 during bending and oscillation, and maintaining the overall structural stability of the composite conductor. Specifically, the overlap rate of the nonwoven fabric on the copper wire stranded layer is 10%~15%.

[0051] Specifically, the nonwoven fabric can be made of polyester fiber nonwoven fabric, polypropylene fiber nonwoven fabric, or other nonwoven fabric materials suitable for cable sheathing. The nonwoven fabric has good flexibility and abrasion resistance, and is wrapped around the outside of multiple tin-plated copper wires in a spiral winding manner to cover and limit the tin-plated copper wires, so as to reduce the loosening or displacement of the tin-plated copper wires during twisting and bending.

[0052] In an optional embodiment, the ratio of the cross-sectional areas of the aramid reinforcing fiber 10, the tin-plated copper wire 20, and the copper foil wire 30 in the cross-section of the composite conductor is 15:72:13.

[0053] Tin-plated copper wire 20, as the main conductive component, is distributed on the outer periphery of aramid reinforcing fiber 10, with aramid reinforcing fiber 10 located in the central region. Copper foil wire 30 is located on the outer side of tin-plated copper wire 20, thus forming a composite conductor structure distributed sequentially from the center outwards. The cross-sectional area ratio also ensures that the components maintain a relatively uniform distribution after stranding and winding, making the outer contour of the composite conductor nearly circular. Considering the structure and cross-sectional distribution of each component, the outer contour of the composite conductor is nearly circular in cross-section, with a roundness deviation of less than or equal to 15%, giving the composite conductor a relatively regular cross-sectional shape, facilitating stable coating of the composite conductor by the subsequent insulating layer 40.

[0054] In an optional embodiment, the insulation layer 40 is made of cross-linked polyethylene (PE) material, which coats the outside of the composite conductor to form the insulation layer 40. After the cross-linked polyethylene compound coats the composite conductor, the insulation layer 40 is formed by extrusion molding. After extrusion cooling, the insulation layer 40 is subjected to irradiation treatment to cross-link the polyethylene material in the insulation layer 40, thereby obtaining an insulation layer 40 with high temperature resistance and environmental resistance. The irradiation treatment can be performed by electron beam irradiation, and as the last process in the cable production process, the irradiation treatment is performed directly after extrusion cooling, without the need for high-temperature processing in a boiler.

[0055] The irradiated insulation layer 40 can improve the long-term temperature resistance of the cable, making the cable suitable for long-term use in environments with temperatures of approximately 125°C to 150°C. In the event of short-term high-temperature conditions such as short circuits, the insulation layer 40 can withstand short-term temperatures of approximately 250°C and is less prone to melting and dripping. Instead, it carbonizes, thereby reducing the impact of melting and dripping of the insulation layer 40 at high temperatures on the insulation performance and safety of the cable.

[0056] Furthermore, the irradiated insulation layer 40 exhibits good oil resistance, aging resistance, ozone resistance, and abrasion resistance, enabling the cable to adapt to applications requiring high environmental resistance, such as automotive wiring harnesses and robot wiring harnesses. The irradiation treatment also improves the stability of the insulation layer 40 during repeated bending, making it less prone to significant surface damage from prolonged bending, thus enhancing the overall bending resistance and service life of the cable.

[0057] In one specific embodiment, after the insulating layer 40 is formed and irradiated, its surface has a matte, frosted texture, which differs from the smooth surface of ordinary wires. Because the insulating layer 40 is made of cross-linked polyethylene material and formed into a final product through irradiation, the entire insulating layer 40 is coated and cured onto the outside of the composite conductor using the same type of polyethylene-based rubber compound, thus forming a continuous insulating coating structure. Compared with the method of forming the insulating layer 40 using a vulcanization process, the irradiation cross-linking process does not produce sulfur precipitation, reducing blooming and whitening phenomena on the surface of the insulating layer 40, and keeping the surface of the insulating layer 40 in a more stable state.

[0058] The following section will conduct performance tests on the high-bending-resistance composite conductor cable provided in the embodiments of this application.

[0059] The cable has the following specific structure: a composite conductor and an insulation layer 40 covering the outside of the composite conductor; The composite conductor comprises aramid reinforcing fiber 10, tin-plated copper wire 20, and copper foil wire 30. The aramid reinforcing fiber 10 has a tensile strength of 3.0~4.5 GPa, an elongation at break of 2.5%~3.5%, an initial modulus of not less than 80 GPa, and a heat shrinkage rate of not more than 1.5% at 150℃. The fineness of the aramid reinforcing fiber 10 is 250D, and the diameter of each aramid reinforcing fiber 10 filament is 9~11 μm. The tin-plated copper wire 20 has a diameter of 0.05±0.005 mm, and there are 165 tin-plated copper wires. The tin-plated copper wires 20 are twisted and wound around the outside of the aramid reinforcing fiber 10 with a twist pitch of 3.5~8 mm. The copper foil wire 30 is spirally wound around the outside of multiple tin-plated copper wires 20, and the thickness of the copper foil wire 30 is 0.02~0.03 mm.

[0060] The cable sample of this embodiment was tested with a cable load capacity of 50g, a swing amplitude of ±45°, and a swing frequency of 30 times / min (43200 times / day).

[0061] The test data is shown in Table 1:

[0062] Table 1 As shown in the table above, the high-bending-resistance composite conductor cable in this embodiment can continuously withstand high-frequency, repeated bending and swinging under the above swing test conditions. After swinging more than 200,000 times, the cable can still maintain normal structural state and performance, without significant breakage or failure due to repeated bending. This indicates that the cable in this embodiment has high swing life and bending resistance, which can meet the dynamic usage scenarios of drones, robots and other devices that need to repeatedly swing or bend for a long time.

[0063] This application also provides an electrical device, including a high-bend-resistant composite conductor cable as described in any of the above embodiments. This cable can be used in electrical devices that require dynamic power supply, such as drones, robots, medical devices, and environmental appliances.

[0064] Specifically, in drones, the cable can be used for electrical connections between the fuselage and moving parts, swinging or bending with the moving parts during flight; in robots, the cable can be used for power supply or signal transmission to moving parts such as robotic arms and robot joints, enabling the cable to adapt to repeated rotation and bending of the robot joints; in medical devices, the cable can be used for electrical connection structures with moving, swinging, or reciprocating motion parts to adapt to repeated bending during device operation; in environmental electrical appliances, the cable can be used for electrical connection parts with moving parts or requiring frequent movement to reduce the possibility of cable fatigue damage during long-term dynamic motion. Because the high-bending-resistant composite conductor cable has high swing life and bending resistance, it can improve the reliability of power supply connections in the aforementioned electrical devices under long-term dynamic operating conditions. The advantages of the high-bending-resistant composite conductor cable in the foregoing embodiments are also present in the electrical devices of this application, and will not be elaborated here.

[0065] It should be noted that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," etc., are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. The directional terms "inner" and "outer" refer to the inside or outside relative to the outline of the component itself. For example, if a device in the drawings is inverted, a device described as "above" or "on top of" other devices or structures will subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein are interpreted accordingly.

[0066] It should also be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this application refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this application.

[0067] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0068] It should also be noted that the above are merely preferred embodiments of this application and do not limit the scope of patent protection of this application. Any equivalent structural or procedural changes made using the content of this application’s specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the scope of patent protection of this application.

Claims

1. A high-bending-resistance composite conductor cable, characterized in that, It includes a composite conductor and an insulating layer covering the outside of the composite conductor; The composite conductor includes: Aramid reinforced fiber; Multiple tin-plated copper wires are twisted and wound around the outside of the aramid reinforcing fiber; Copper foil wire is wound around the outside of multiple tin-plated copper wires; In the cross-section of the composite conductor, the aramid reinforcing fiber is located in the central region, and multiple tin-plated copper wires are distributed circumferentially along the aramid reinforcing fiber and surround the aramid reinforcing fiber to form a copper wire stranded layer. The copper foil wire is located radially outside the copper wire stranded layer and spirally wound around the outer periphery of the copper wire stranded layer along the axial direction of the composite conductor.

2. The high-bending-resistance composite conductor cable according to claim 1, characterized in that, The tin-plated copper wire has a diameter of 0.05±0.005mm and includes an inner copper layer and an outer tin layer. The thickness of the outer tin layer is 0.4~0.8μm.

3. The high-bending-resistance composite conductor cable according to claim 2, characterized in that, The number of the aforementioned tin-plated copper wires is 165.

4. The high-bending-resistance composite conductor cable according to claim 1, characterized in that, The twist pitch of the tin-plated copper wire is 3.5~8mm.

5. The high-bending-resistance composite conductor cable according to claim 1, characterized in that, The thickness of the copper foil wire is 0.02~0.03mm.

6. The high-bending-resistance composite conductor cable according to claim 1, characterized in that, The aramid-reinforced fiber has a tensile strength of 3.0~4.5GPa, an elongation at break of 2.5%~3.5%, an initial modulus of not less than 80GPa, and a heat shrinkage rate of not more than 1.5% at 150℃.

7. The high-bending-resistance composite conductor cable according to claim 6, characterized in that, The fineness of the aramid-reinforced fiber is 250D, and the diameter of the single filament of the aramid-reinforced fiber is 9~11μm.

8. The high-bending-resistance composite conductor cable according to claim 1, characterized in that, The composite conductor also includes a nonwoven fabric, which is spirally wound around the outside of the multiple tin-plated copper wires.

9. The high-bending-resistance composite conductor cable according to any one of claims 1 to 8, characterized in that, In the cross-section of the composite conductor, the ratio of the cross-sectional areas of the aramid reinforcing fiber, the tin-plated copper wire, and the copper foil wire is 15:72:

13.

10. An electrical device, characterized in that, Including the high bending-resistant composite conductor cable as described in any one of claims 1 to 9.

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