Large-current-carrying-capacity flexible copper wire row cable

Abstract

The utility model discloses a large-current-carrying-capacity flexible copper wire row cable, which relates to the technical field of flexible copper wire row cables and comprises solid copper bars distributed in a stacked manner, a composite insulating layer is filled and wrapped on the outer wall of the solid copper bars, a dynamic shielding layer is wound on the outer wall of the composite insulating layer, and an armored reinforcing layer is mounted on the dynamic shielding layer. A PVC sheath layer is formed on the outer wall of the armored reinforcing layer through extrusion molding; according to the utility model, the three layers of copper bars are staggered and stacked in a stepped manner, so that the skin effect and the proximity effect are effectively reduced, the current-carrying capacity is obviously improved compared with that of a single-layer copper bar, the effective contact area is increased, the temperature rise and the electric energy loss are reduced, and the installed composite insulating layer enhances heat dissipation through silicon rubber filled boron nitride particles. The polyimide film is coated outside to form a longitudinal heat conduction channel, so that heat diffusion is further accelerated, stability under a high-temperature working condition is ensured, and the overall application range of the cable is widened.

Description

Technical Field

[0001] The utility model relates to the technical field of flexible copper wire row cables, in particular to a large current-carrying flexible copper wire row cable. Background Art

[0002] Copper busbar cable refers to a power transmission cable with copper busbar conductor (single or multi-layer) as the core, which is commonly used in high current carrying and high voltage industrial and power systems;

[0003] Affected by the conductor material and structure, solid copper busbars have a large cross-sectional area and excellent conductivity. The current carrying capacity can reach 1.5-2 times that of multi-strand cables with the same cross-sectional area. They are suitable for high-power equipment. At the same time, they have low DC resistance and about 30% lower power loss than aluminum busbars. They are economical in long-term operation. The rigid structure provides support and can bear its own weight without additional brackets. They are suitable for bus ducts, distribution cabinets and other scenarios. However, due to the material of the copper busbar, the overall flexibility and heat dissipation of the cable are poor. It is necessary to expand the application range of copper busbar cables through flexible and lightweight designs.

[0004] Therefore, we propose a flexible copper wire bus cable with large current carrying capacity. Utility Model Content

[0005] The utility model aims to provide a flexible copper wire bus cable with large current carrying capacity to solve the problems raised in the background technology.

[0006] To achieve the above-mentioned purpose, the utility model provides the following technical solutions: a large current-carrying flexible copper wire busbar cable, comprising stacked solid copper busbars, the outer wall of the solid copper busbars is filled and wrapped with a composite insulation layer, the outer wall of the composite insulation layer is wrapped with a dynamic shielding layer, an armor reinforcement layer is arranged outside the dynamic shielding layer, and the outer wall of the armor reinforcement layer is extruded with a PVC sheath layer;

[0007] The solid copper bar is a three-layer solid T2 copper bar stacked structure, and the thickness of each layer of copper bar is 3mm. The contact surface of the solid copper bar is formed into a micro-groove structure by milling process;

[0008] The middle copper bars of the three solid copper bars are laterally offset by 5.5 mm relative to the upper and lower layers, forming a stepped dislocation.

[0009] Furthermore, the composite insulating layer comprises silicone rubber, boron nitride particles and a polyimide film, the silicone rubber is added with boron nitride particles, and the outer wall of the silicone rubber is coated with a 0.3 mm polyimide film.

[0010] Furthermore, the armor reinforcement layer adopts a composite braided structure of aramid fiber and copper-plated steel wire, and forms a flexible armor layer after being impregnated and cured with epoxy resin.

[0011] Compared with the prior art, the beneficial effects of the utility model are:

[0012] In the utility model, the large current-carrying flexible copper wire busbar cable provided has significantly improved performance and application range through multiple structural optimizations. It adopts a three-layer copper busbar stepped staggered stacking design, with the middle layer laterally offset, combined with a contact surface micro-groove structure, which effectively reduces the skin effect and proximity effect, and significantly improves the current carrying capacity compared to a single-layer copper busbar, while increasing the effective contact area and reducing temperature rise and power loss.

[0013] Secondly, the polyimide film coating forms a longitudinal heat conduction channel, which further accelerates heat diffusion and ensures stability under high temperature conditions. After comprehensive optimization, the cable is significantly superior to traditional copper busbar cables in terms of current carrying capacity, flexibility, heat dissipation efficiency, anti-interference ability and reliability. It is especially suitable for high electromagnetic interference and high-power scenarios such as new energy equipment and industrial robots. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a schematic diagram of the overall structure of the utility model's large current-carrying flexible copper wire busbar cable;

[0015] Figure 2 This is a schematic diagram of the cross-sectional structure of the utility model's large current-carrying flexible copper wire busbar cable;

[0016] Figure 3 This is a side view structural schematic diagram of the utility model's large current-carrying flexible copper wire busbar cable.

[0017] In the figure: 1. solid copper busbar; 2. composite insulation layer; 201. silicone rubber; 202. boron nitride particles; 203. polyimide film; 3. dynamic shielding layer; 4. armor reinforcement layer; 5. PVC sheath layer. DETAILED DESCRIPTION

[0018] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0019] See also Figure 1-3 , the utility model provides a technical solution:

[0020] like Figure 1The conductor of the high current carrying flexible copper wire busbar cable shown in the figure is composed of multiple layers of copper plates, and the solid copper busbar 1 is made of T2 copper plate, which is cut into copper bars with the same length and width. The contact surface of each layer of copper busbar is processed by CNC milling machine with parallel grooves with a depth of 0.2mm and a spacing of 1.7mm. The surface is tinned with a thickness controlled at 5μm to enhance oxidation resistance. The solid copper busbar 1 is divided into three pieces, such as Figure 3 As shown, the three-layer copper busbar is stacked in the order of "upper-middle-lower", among which the middle copper busbar is offset 5.5mm laterally to form a stepped dislocation structure. The alternating distribution of the copper busbars can disperse the current path, reduce the accumulation of high-frequency current on the conductor surface and the magnetic field interference between adjacent conductors. The current carrying capacity of the traditional aligned stacked copper busbar is 1200A, while the alternating distribution design increases the current carrying capacity to 1600A, the efficiency is increased by 33%, and the skin effect and proximity effect are significantly reduced. The current carrying capacity is increased by more than 35% compared with the single-layer copper busbar, the DC resistance is reduced by 20%, and the power loss is reduced. At the same time, the micro-groove structure on the contact surface of the solid copper busbar 1 increases the effective contact area, reduces the contact resistance, and further reduces the temperature rise;

[0021] As for the insulating layer installed on the outer periphery of the solid copper busbar 1, silicone rubber 201 is selected to wrap and cover the stacked solid copper busbar 1. At the same time, the silicone rubber 201 also supports the staggered solid copper busbar 1, and the boron nitride particles 202 filled in the silicone rubber 201 improve the overall heat dissipation effect. Similar to the invention patent "a composite cable material with thermal conductivity and insulation enhanced by adding modified boron nitride silicone rubber", the boron nitride after coupling modification and methyl vinyl silicone rubber are mixed and kneaded to make fillers and added to the matrix low-density polyethylene. The fillers can be evenly dispersed with the matrix, have good interface compatibility, and improve the thermal conductivity of the material. Therefore, the heat between the copper busbars can be quickly diffused to the surface, and the temperature rise is reduced by 15-20K compared with the traditional silicone insulation. Figure 2 As shown, it is located outside the silicone rubber 201 and is covered with a 0.3 mm polyimide film 203 to form a longitudinal heat conduction channel to achieve rapid heat diffusion;

[0022] The composite insulation layer 2 is wrapped with a dynamic shielding layer 3, which is made of φ0.15mm tinned copper wire braided mesh with a braiding density of ≥90%, and a shape memory alloy wire is embedded in the shielding layer. When the cable is stretched by external force, the alloy wire triggers the contraction mechanism to maintain the integrity of the shielding and effectively suppress electromagnetic interference. The armor reinforcement layer 4 installed on the outside is made of a composite braided structure of aramid fiber and copper-plated steel wire. After epoxy resin impregnation and curing, a flexible armor layer is formed to keep the cable free to curl and meet the mechanical protection requirements under complex working conditions.

[0023] The outermost PVC sheath layer 5 adopts the extrusion process, heating the flame-retardant PVC particles to 180℃ to melt, and then extruding them onto the outside of the armor layer through a mold. The sheath thickness is 2.5mm, and anti-slip texture is pressed on the surface. Through structural optimization, the overall weight of the cable is 20% lighter than that of multi-strand cables with the same cross-sectional area, and no additional bracket support is required. It can be directly laid in a small space or moving parts. By improving the flexible copper wire bus cable, it is significantly superior to the traditional copper bus cable in terms of current carrying capacity, flexibility, heat dissipation and reliability. It is especially suitable for new energy equipment, industrial robots and high electromagnetic interference scenarios.

[0024] The above contents are merely examples and explanations of the structure of the utility model. The technicians in this technical field may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the structure of the utility model or exceed the scope defined in the claims, they should all fall within the protection scope of the utility model.

[0025] In the description of this specification, the description with reference to the terms "one embodiment", "example", "specific example", etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the utility model. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0026] The preferred embodiments of the utility model disclosed above are only used to help explain the utility model. The preferred embodiments do not describe all the details in detail, nor do they limit the utility model to only specific implementation methods. Obviously, many modifications and changes can be made according to the content of this specification. This specification selects and specifically describes these embodiments in order to better explain the principles and practical applications of the utility model, so that technicians in the relevant technical field can well understand and use the utility model. The utility model is only limited by the claims and their full scope and equivalents.

Claims

1. A flexible copper wire busbar cable with large current carrying capacity, characterized in that: The invention comprises a stacked solid copper busbar (1), wherein the outer wall of the solid copper busbar (1) is filled and wrapped with a composite insulation layer (2), the outer wall of the composite insulation layer (2) is wrapped with a dynamic shielding layer (3), an armor reinforcement layer (4) is arranged outside the dynamic shielding layer (3), and the outer wall of the armor reinforcement layer (4) is extruded with a PVC sheath layer (5); The solid copper busbar (1) is a three-layer solid T2 copper busbar laminated structure, and the thickness of each layer of copper busbar is 3 mm. The contact surface of the solid copper busbar (1) is formed into a micro-groove structure by a milling process; The middle copper bars of the three solid copper bars (1) are laterally offset by 5.5 mm relative to the upper and lower layers, forming a stepped dislocation.

2. A high current carrying capacity flexible copper wire busbar cable according to claim 1, characterized in that: The composite insulating layer (2) comprises silicone rubber (201), boron nitride particles (202) and a polyimide film (203); the boron nitride particles (202) are added to the silicone rubber (201); and the outer wall of the silicone rubber (201) is coated with a 0.3 mm polyimide film (203).

3. A high current carrying capacity flexible copper wire busbar cable according to claim 2, characterized in that: The armor reinforcement layer (4) adopts a composite braided structure of aramid fibers and copper-plated steel wires, and is impregnated and cured with epoxy resin to form a flexible armor layer.

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