Connecting cable for clean energy

Abstract

The utility model relates to the technical field of photovoltaic cables, in particular to a connecting cable for clean energy, which comprises a conductor, an insulating layer and a sheath. The conductor comprises a plurality of layers of stranded structures, each layer of stranded structure comprises an aluminum alloy wire bundle, and the aluminum alloy wire bundle on the outer layer is stranded on the outer side of the aluminum alloy wire bundle on the inner layer; and a composite fiber tow is arranged between the inner-layer stranded structure and the outer-layer stranded structure. According to the connecting cable of the aluminum alloy conductor provided by the utility model, the bending capability of the conductor is improved through the multi-layer multi-stranded aluminum alloy wire bundles, and the tensile property of the conductor is improved through adding the aramid fiber wire bundles in the conductor, so that the probability of creep deformation or wire breakage of the small-diameter aluminum alloy monofilaments in a tension or bending state can be reduced; the aluminum alloy conductor can replace an original copper conductor to be connected with a cable, so that the production cost is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of wires and cables, in particular to a connecting cable for clean energy. Background Art

[0002] Clean energy interconnect cables are cables used to connect various devices or components to transmit power in renewable energy power generation systems such as wind, solar, and hydropower, as well as in electric vehicle charging facilities and energy storage systems. In particular, interconnect cables for photovoltaic energy storage are primarily used to connect power between battery modules on the DC side of battery energy storage systems, between battery clusters, between battery clusters and combiner boxes, or between battery clusters and energy storage converters.

[0003] Currently, photovoltaic connection cables mainly include conductors, insulation layers and sheath layers. The conductors usually use pure copper or tinned copper cores, and the insulation layers and sheath layers are made of polyvinyl chloride and polyolefin materials respectively. Due to its high hardness, the 8000 series aluminum alloy cannot meet the bending performance requirements of the cable, which is not conducive to connecting the cable between multiple solar panels and junction boxes. Therefore, the conductors are formed by twisting fine copper wires with a diameter of 0.5 mm, which also leads to the high cost of photovoltaic connection cables. Summary of the Invention

[0004] In view of the technical problems existing in the photovoltaic connection cables in the prior art, the first aspect of the present invention provides a connection cable for clean energy, comprising a conductor, an insulation layer and a sheath;

[0005] The conductor comprises a multi-layer twisted structure, each layer of the twisted structure comprises an aluminum alloy wire bundle, wherein the aluminum alloy wire bundle of the outer layer is twisted on the outside of the aluminum alloy wire bundle of the inner layer;

[0006] A composite fiber tow is provided between the inner layer twisted structure and the outer layer twisted structure, wherein the composite fiber tow comprises a twisted aramid tow and a water-blocking tow;

[0007] An elastomer is also filled between the inner layer twisted structure and the outer layer twisted structure;

[0008] The conductor and the insulating layer are provided with a copper wire braiding layer.

[0009] Preferably, the conductor includes a three-layer twisted structure, the first layer twisted structure, the second layer twisted structure and the third layer twisted structure are distributed from the inside to the outside, the first layer twisted structure includes a bundle of aluminum alloy wire bundles, the second layer twisted structure includes six bundles of aluminum alloy wire bundles twisted outside the first layer twisted structure, and the third layer twisted structure includes twelve bundles of aluminum alloy wire bundles twisted outside the second layer twisted structure.

[0010] Preferably, the aluminum alloy wire bundle is a three-layer twisted structure of 1+6+12.

[0011] Preferably, the re-twisted pitch-diameter ratio of the third layer twisted structure is 8-10, and the re-twisted pitch-diameter ratio of the second layer twisted structure is 12-14.

[0012] Preferably, the twisted pitch-to-diameter ratio of the aluminum alloy wire bundles in the first layer twisted structure is 20~30, the twisted pitch-to-diameter ratio of the aluminum alloy wire bundles in the second layer twisted structure is 18~22, and the twisted pitch-to-diameter ratio of the aluminum alloy wire bundles in the third layer twisted structure is 12~16.

[0013] Preferably, the diameter of the aluminum alloy single wire in the aluminum alloy wire bundle is 0.15~0.30mm.

[0014] Preferably, a plurality of first composite fiber bundles are provided between the second layer twisted structure and the third layer twisted structure, and a plurality of second composite fiber bundles are provided between the third layer twisted structure and the copper wire braided layer.

[0015] Preferably, the first composite fiber tow and the second composite fiber tow both include an aramid tow located in the center and a plurality of water-blocking tows twisted on the outer wall of the aramid tow.

[0016] Preferably, the elastomer comprises nylon filaments.

[0017] Preferably, the insulating layer comprises a cross-linked polyethylene insulating layer, and the sheath comprises a cross-linked low-smoke halogen-free flame-retardant polyolefin sheath.

[0018] Compared with the prior art, the advantages of the present invention are:

[0019] The connecting cable with an aluminum alloy conductor proposed by the utility model improves the bending ability of the conductor by using multiple layers of twisted aluminum alloy wire bundles. At the same time, the tensile strength of the conductor is improved by adding aramid wire bundles in the conductor, which can reduce the probability of creep or wire breakage of thin-diameter aluminum alloy single wires under tension or bending. The copper wire braided layer provided between the conductor and the insulation layer restrains the conductor. When the insulation layer of the connecting cable is stripped, the twisted conductor can be prevented from spreading, thereby facilitating connection with the connector. The aluminum alloy conductor can replace the original copper conductor connecting cable to reduce production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The accompanying drawings are not intended to be drawn to scale. In the accompanying drawings, each identical or nearly identical component shown in various figures may be represented by the same reference numeral. For the sake of clarity, not every component is labeled in every figure. Embodiments of various aspects of the present invention will now be described by way of example and with reference to the accompanying drawings, in which:

[0021] Figure 1 It is a structural schematic diagram of a clean energy connection cable shown in the utility model. DETAILED DESCRIPTION

[0022] In order to better understand the technical content of the present invention, specific embodiments are given and described below with reference to the accompanying drawings.

[0023] Combine Figure 1 As shown, the first aspect of the present invention proposes a connecting cable for clean energy, which mainly includes a conductor 10, an insulating layer 30 and a sheath 40. The conductor 10 of the present application includes a multi-layer twisted structure, and each layer of the twisted structure includes an aluminum alloy wire bundle, wherein the outer layer of the aluminum alloy wire bundle is twisted on the outside of the inner layer of the aluminum alloy wire bundle.

[0024] Optionally, the aluminum alloy wire bundle uses 8000 series aluminum alloy monofilaments with a diameter of 0.15 mm ~ 0.30 mm. The 8000 series aluminum alloy has good electrical conductivity and a conductivity slightly lower than that of copper, which can reduce the loss of electric energy and improve power transmission efficiency. Compared with copper conductors, aluminum alloy has a lower price. Under the premise of meeting the same electrical conductivity, it has a significant price advantage. In addition, by reducing the diameter of the monofilament and setting a double-twisted conductor structure, the bending performance of the cable can be improved.

[0025] In an optional embodiment, if Figure 1 As shown, the conductor 10 includes a three-layer twisted structure, wherein the first layer twisted structure 11, the second layer twisted structure 12 and the third layer twisted structure 13 are distributed from the inside to the outside. The first layer twisted structure 11 includes a bundle of aluminum alloy wire bundles, the second layer twisted structure 12 includes six bundles of aluminum alloy wire bundles twisted outside the first layer twisted structure 11, and the third layer twisted structure 13 includes twelve bundles of aluminum alloy wire bundles twisted outside the second layer twisted structure 12.

[0026] Among them, each bundle of aluminum alloy wires has a three-layer twisted structure of 1+6+12.

[0027] In an optional embodiment, the re-twisting pitch ratio of the third layer twisted structure 13 is 8 to 10, and the re-twisting pitch ratio of the second layer twisted structure 12 is 12 to 14. The smaller re-twisting pitch ratio allows the twisted conductor to have better bending performance, especially reducing the stress on the conductor strands in a bent state.

[0028] Furthermore, the twisted pitch-diameter ratio of the aluminum alloy wire bundles in the first layer twisted structure 11 is 20-30. Specifically, the twisted pitch-diameter ratio of the aluminum alloy wires in the middle layer is 30, and the twisted pitch-diameter ratio of the aluminum alloy wires in the outer layer is 20.

[0029] Furthermore, the twisted pitch-diameter ratio of the aluminum alloy wire bundles in the second layer twisted structure 12 is 18-22. Specifically, the twisted pitch-diameter ratio of the aluminum alloy wires in the middle layer is 22, and the twisted pitch-diameter ratio of the aluminum alloy wires in the outer layer is 18.

[0030] Furthermore, the twisted pitch-diameter ratio of the aluminum alloy wire bundles in the third layer twisted structure 13 is 12-16. Specifically, the twisted pitch-diameter ratio of the aluminum alloy wires in the middle layer is 16, and the twisted pitch-diameter ratio of the aluminum alloy wires in the outer layer is 12.

[0031] In this way, by reducing the twisted pitch ratio of the aluminum alloy monofilament from the inside to the outside, the conductor is made easier to bend, and the aluminum alloy monofilament can reduce the stress during bending, thereby reducing the probability of creep or even fatigue fracture of the aluminum alloy monofilament.

[0032] Furthermore, a composite fiber bundle is provided between the inner layer twisted structure and the outer layer twisted structure.

[0033] The composite fiber tow includes a twisted aramid tow and a water-blocking tow.

[0034] The tensile strength of the conductor can be improved by providing an aramid tow, especially when the diameter of the conductor monofilament is thin. The aramid tow can bear the tensile strength of the conductor, thereby preventing the aluminum alloy monofilament from bearing tensile stress and creep of the aluminum alloy monofilament.

[0035] By filling the water-blocking bundles between the single wires, the water vapor between the metal wires can be absorbed, making the conductor cross-section dense and playing a water-blocking role.

[0036] Optionally, a plurality of first composite fiber bundles 15 are provided between the second layer twisted structure 12 and the third layer twisted structure 13 , and a plurality of second composite fiber bundles 16 are provided between the third layer twisted structure 13 and the copper wire braided layer 20 .

[0037] Specifically, the first composite fiber tow 15 and the second composite fiber tow 16 both include an aramid tow located in the center and a plurality of water-blocking tows twisted on the outer wall of the aramid tow.

[0038] Furthermore, an elastomer 14 is filled between the inner layer twisted structure and the outer layer twisted structure. The filled elastomer 14 further increases the bending performance of the conductor, especially reduces the stress of the metal wire in the bending state, and improves the service life of the cable.

[0039] Preferably, the elastic body 14 comprises nylon filaments.

[0040] Furthermore, a copper wire braided layer 20 is provided between the conductor 10 and the insulating layer 30. The copper wire braided layer 20 can provide a binding effect and a shielding effect on the twisted conductors.

[0041] In addition, since the diameter of the monofilament is relatively thin, when stripping the insulation, the inner layer of aluminum alloy monofilament can be limited by the copper wire braided layer 20 to prevent the aluminum alloy monofilament from bending outward and becoming scattered, which is conducive to the connection with the connector.

[0042] Optionally, the copper wire braided layer 20 is formed by cross-braiding copper wires with a diameter of 0.5 mm or greater at an angle of 45°.

[0043] In the above embodiment, the insulation layer 30 includes a cross-linked polyethylene insulation layer. The cross-linked polyethylene insulation layer has excellent heat resistance and will not decompose and carbonize below 200°C. The long-term working temperature can reach 90°C and the thermal life can reach 40 years, meeting the cable reliability requirements.

[0044] The sheath 40 includes a cross-linked low-smoke halogen-free flame-retardant polyolefin sheath. The cross-linked low-smoke halogen-free flame-retardant polyolefin sheath has good weather resistance, UV resistance, and chemical corrosion resistance, is suitable for use in harsh environments, and meets the use requirements of photovoltaic connection cables in sunlight and exposed environments.

[0045] In combination with the above embodiments, the connecting cable with an aluminum alloy conductor proposed by the present invention improves the bending ability of the conductor by using multi-layer twisted aluminum alloy wire bundles, and at the same time improves the tensile performance of the conductor by adding aramid wire bundles in the conductor, which can reduce the probability of creep or wire breakage of thin-diameter aluminum alloy monofilaments under tension or bending. The copper wire braided layer arranged between the conductor and the insulation layer restrains the conductor. When the insulation layer of the connecting cable is stripped, the twisted conductor can be prevented from spreading, which is conducive to connection with the connector. This aluminum alloy conductor can replace the original copper conductor connecting cable to reduce production costs.

[0046] While the present invention has been described above with reference to preferred embodiments, this is not intended to limit the present invention. Persons skilled in the art will readily appreciate that various modifications and variations may be made without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the claims.

Claims

1. A connection cable for clean energy, characterized in that: It comprises a conductor (10), an insulating layer (30) and a sheath (40); The conductor (10) comprises a multi-layer twisted structure, each layer of the twisted structure comprises an aluminum alloy wire bundle, wherein the aluminum alloy wire bundle of the outer layer is twisted on the outside of the aluminum alloy wire bundle of the inner layer; A composite fiber tow is provided between the inner layer twisted structure and the outer layer twisted structure, wherein the composite fiber tow comprises a twisted aramid tow and a water-blocking tow; An elastic body (14) is also filled between the inner layer twisted structure and the outer layer twisted structure; The conductor (10) and the insulating layer (30) are provided with a copper wire braided layer (20).

2. The clean energy connection cable according to claim 1, characterized in that: The conductor (10) includes a three-layer twisted structure, wherein a first layer twisted structure (11), a second layer twisted structure (12) and a third layer twisted structure (13) are distributed from the inside to the outside, the first layer twisted structure (11) includes a bundle of aluminum alloy wire bundles, the second layer twisted structure (12) includes six bundles of aluminum alloy wire bundles twisted outside the first layer twisted structure (11), and the third layer twisted structure (13) includes twelve bundles of aluminum alloy wire bundles twisted outside the second layer twisted structure (12).

3. The clean energy connection cable according to claim 2, characterized in that: The aluminum alloy wire bundle is a three-layer twisted structure of 1+6+12.

4. The clean energy connection cable according to claim 2, characterized in that: The re-twisted stranded pitch ratio of the third layer twisted structure (13) is 8-10, and the re-twisted stranded pitch ratio of the second layer twisted structure (12) is 12-14.

5. The clean energy connection cable according to claim 3, characterized in that: The twisted pitch-to-diameter ratio of the aluminum alloy wire bundles in the first layer twisted structure (11) is 20-30, the twisted pitch-to-diameter ratio of the aluminum alloy wire bundles in the second layer twisted structure (12) is 18-22, and the twisted pitch-to-diameter ratio of the aluminum alloy wire bundles in the third layer twisted structure (13) is 12-16.

6. The clean energy connection cable according to any one of claims 1 to 5, characterized in that: The diameter of the aluminum alloy single wire in the aluminum alloy wire bundle is 0.15~0.30mm.

7. The clean energy connection cable according to claim 2, characterized in that: A plurality of first composite fiber bundles (15) are provided between the second layer twisted structure (12) and the third layer twisted structure (13), and a plurality of second composite fiber bundles (16) are provided between the third layer twisted structure (13) and the copper wire braided layer (20).

8. The clean energy connection cable according to claim 7, characterized in that: The first composite fiber bundle (15) and the second composite fiber bundle (16) both comprise an aramid bundle located in the center and a plurality of water-blocking bundles twisted on the outer wall of the aramid bundle.

9. The clean energy connection cable according to claim 1, characterized in that: The elastic body (14) comprises nylon filaments.

10. The clean energy connection cable according to claim 1, characterized in that: The insulating layer (30) comprises a cross-linked polyethylene insulating layer, and the sheath (40) comprises a cross-linked low-smoke halogen-free flame-retardant polyolefin sheath.

Images