Salt-fog-resistant environment aluminum alloy power cable
By using round core wires and multi-layer wire structures in aluminum alloy cables, combined with steel core aluminum alloy and aramid yarn braided layers, the corrosion and conductivity problems of aluminum alloy cables in high salt spray environments are solved, the cable's water resistance, corrosion resistance and tensile strength are improved, and its service life is extended.
Patent Information
- Application Number
- CN202422554895.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-22
- Publication Date
- 2025-09-16
- Estimated Expiration
- 2034-10-22
AI Technical Summary
Aluminum alloy power cables are susceptible to seawater corrosion in high salt spray environments, resulting in a shortened service life. Existing water-blocking yarn filling requirements are high and increase conductor contact resistance, affecting conductive performance.
It adopts a round core wire and a multi-layer semi-circular arc wire structure tightly pressed on the outer wall of the core wire, combined with a steel core aluminum alloy structure and an aramid yarn braided layer to form a dense conductor, enhance water resistance and conductivity, and improve tensile strength through cross-braiding layers.
It achieves effective water resistance and corrosion resistance in high salt fog environments, improves the tensile strength and service life of the conductor, and meets the needs of offshore or offshore facilities.
Smart Images
Figure CN223347538U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of wires and cables, in particular to a salt-fog environment-resistant aluminum alloy power cable. Background Art
[0002] Aluminum alloy power cables have excellent mechanical and electrical properties, making them particularly suitable for use as power cables for wind power transmission. They usually include steel-core aluminum stranded wire conductors, insulation layers, and sheath structures. The sheaths are made of corrosion-resistant, flame-retardant polyvinyl chloride. When used in high-humidity, high-salt-fog environments near the sea, aluminum alloy cables are susceptible to erosion by seawater, which in turn affects their service life.
[0003] Therefore, current cables usually install water-blocking yarn inside the twisted conductors. When water vapor invades, the gaps between the conductor wires are filled by the expansion of the water-blocking yarn to achieve a water-blocking effect, thereby avoiding electrochemical corrosion between the aluminum conductor and the steel conductor. However, the twisted conductors have many gaps, and the filling requirements for the water-blocking yarn are high. Otherwise, a good water-blocking effect cannot be achieved. If necessary, water-blocking powder needs to be filled in combination, which increases the contact resistance of the conductor and is not conducive to improving the conductive performance of the conductor. Utility Model Content
[0004] In view of the technical problems existing in the prior art aluminum alloy power cables, the first aspect of the present invention proposes a salt spray resistant aluminum alloy power cable, comprising:
[0005] A conductor, the conductor comprising a core wire having a circular cross-section and multiple layers of profiled wire tightly pressed against the outer wall of the core wire, each layer of the profiled wire comprising a pair of mutually engaged profiled wire bodies, the profiled wire bodies having a cross-sectional structure of an arc plate, comprising an inner arc surface and an outer arc surface, the inner arc surface and the outer arc surface corresponding to the corresponding circles being concentric;
[0006] A composite braided layer wrapped around the outer wall of the conductor;
[0007] an insulating layer, covering an outer wall of the composite braided layer;
[0008] A sheath layer, covering the outer wall of the insulating layer;
[0009] The core wire is an aluminum-clad steel structure, comprising a steel core structure and an aluminum alloy structure. The cross-sectional shape of the steel core structure is circular, and the cross-sectional shape of the aluminum alloy structure is annular, surrounding the outer wall of the steel core structure.
[0010] A pair of the profiled wire bodies of each layer of the profiled wire are matched with each other to form an annular structure surrounding the core wire or the outer wall of the profiled wire of the inner layer.
[0011] Preferably, the profile body is further provided with two side surfaces, and the two side surfaces of the profile body are located in the same plane. When a pair of the profile bodies are matched with each other, the corresponding side surfaces are fitted together to form a joint surface parallel to the cable axis.
[0012] Preferably, the multiple layers of the profile lines are divided into odd-numbered layers and even-numbered layers, wherein the bonding surfaces of the profile lines of the odd-numbered layers do not overlap with the bonding surfaces of the profile lines of the even-numbered layers.
[0013] Preferably, the bonding surfaces of the profile lines of the odd-numbered layers are perpendicular to the bonding surfaces of the profile lines of the even-numbered layers.
[0014] Preferably, the thickness of any layer of the profile is the same.
[0015] Preferably, the diameter of the core wire is 2 to 3 mm, and the diameter ratio of the steel core structure to the aluminum alloy structure is 1:2 to 1:3.
[0016] Preferably, the composite braided layer includes an inner braided layer, a longitudinally wrapped shielding layer and an outer braided layer, the inner braided layer includes a semi-conductive wrapping layer wrapped around the outer wall of the conductor and an aramid braided layer woven on the outer wall of the semi-conductive wrapping layer, the longitudinally wrapped shielding layer includes a longitudinally wrapped copper-plastic composite tape, and the outer braided layer includes a mixed braided layer of copper wire and aramid wire bundle.
[0017] Preferably, the semi-conductive wrapping layer includes a semi-conductive EPDM rubber insulating wrapping tape with a wrapping overlap rate of 30% to 50%, the aramid braided layer includes cross-woven aramid fibers, the angle between the aramid fibers and the cable axis is less than 45°, and the braiding density of the aramid braided layer is 10% to 20%.
[0018] Preferably, the outer braided layer is a cross-braided structure, wherein the ratio of the number of copper wires to the number of aramid fiber bundles is 5:1 to 10:1.
[0019] Preferably, the insulating layer comprises a cross-linked polyethylene insulating layer, and the sheath layer comprises a polyvinyl chloride sheath layer.
[0020] Compared with the prior art, the advantages of the present invention are:
[0021] The utility model adopts a circular core wire and a multi-layer semi-circular arc wire structure tightly pressed on the outer wall of the core wire, which can form a high-conductor structure with a high filling factor. The conductor structure is dense, which can achieve good water resistance and conductivity, and achieve good corrosion resistance. At the same time, steel wire is embedded in the conductor, and a braided layer with aramid yarn bundles is provided on the outside, so that the cable has better tensile resistance, which can increase the strength and creep resistance of the aluminum alloy conductor, and make the cable have higher reliability and service life, meeting the use requirements of offshore or offshore facilities. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] 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:
[0023] Figure 1 This is a schematic structural diagram of the salt spray resistant aluminum alloy power cable shown in the present invention;
[0024] Figure 2 This is a schematic diagram of the cross-sectional structure of the salt spray resistant aluminum alloy power cable shown in the present invention;
[0025] Figure 3 This is a schematic structural diagram of the inner braided layer shown in the present invention;
[0026] Figure 4 It is a structural schematic diagram of the outer braided layer shown in the present invention. DETAILED DESCRIPTION
[0027] 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.
[0028] Combine Figure 1 and Figure 2 As shown, the first aspect of the present invention provides a salt spray resistant aluminum alloy power cable, comprising a conductor 10 , a composite braided layer 20 , an insulating layer 30 and a sheath layer 40 .
[0029] In order to improve the filling factor of the conductor, the gap in the entire cable cross section should be as small as possible, such as Figure 2 As shown, the conductor 10 includes a core wire 11 with a circular cross-section and a multi-layer profile 12 tightly pressed against the outer wall of the core wire 11. Each layer of profile 12 includes a pair of profile bodies that are aligned with each other. The cross-sectional structure of the profile body is an arc plate shape, including an inner arc surface and an outer arc surface, and the circles corresponding to the inner arc surface and the outer arc surface are concentric.
[0030] Thus, by arranging the multi-layer profile wire 12 on the outer layer of the core wire 11, the cross section of the conductor is made into a dense circular structure to prevent the existing gaps from invading water vapor with high salt content, and the multi-layer profile wire 12 can flexibly obtain conductor diameters of different specifications.
[0031] Since there are usually strong winds and waves when cables are laid near the coast or in offshore equipment, and the creep resistance of aluminum alloy conductors is poor, in order to increase the tensile strength of the conductor, the core wire 11 is an aluminum-clad steel structure. The core wire 11 includes a steel core structure 111 and an aluminum alloy structure 112. The cross-sectional shape of the steel core structure 111 is circular, and the cross-sectional shape of the aluminum alloy structure 112 is annular, which is surrounded by the outer wall of the steel core structure 111.
[0032] By arranging the steel core structure 111 in the core wire 11 , the tensile strength of the conductor can be improved, and the outer wall of the steel core structure 111 surrounded by the aluminum alloy structure 112 can provide the steel core structure 111 with better corrosion resistance.
[0033] In an optional embodiment, the preparation of the core wire 11 includes the steps of steel core pretreatment, aluminum alloy casting, drawing and stranding, and heat treatment. The steel core pretreatment includes cleaning and rust removal of the steel core to ensure a clean and impurity-free surface. This helps to improve the bonding strength between the steel core and the aluminum alloy. The aluminum alloy casting includes pouring molten aluminum alloy into a mold containing the steel core to ensure a good bonding between the aluminum alloy and the steel core.
[0034] After casting, the aluminum alloy and steel core composite material needs to be drawn and twisted. Drawing can reduce the diameter of the wire and improve its compactness and conductivity, while twisting helps to enhance the tensile strength and bending resistance of the wire. Finally, the wire after drawing and twisting is heat treated to eliminate internal stress and improve the mechanical properties and conductivity of the wire.
[0035] In an optional embodiment, the diameter of the core wire 11 is 2 to 3 mm, and the diameter ratio of the steel core structure 111 to the aluminum alloy structure 112 is 1:2 to 1:3.
[0036] Combine Figure 2 As shown, a pair of profile bodies of each layer of profile 12 are matched with each other to form an annular structure surrounding the core wire 11 or the outer wall of the inner layer profile 12.
[0037] The profile body is also provided with two side surfaces, and the two side surfaces of the profile body are located in the same plane. When a pair of profile bodies are matched with each other, the corresponding side surfaces are fitted together to form a joint surface parallel to the cable axis.
[0038] In this way, after a pair of profile bodies are aligned with each other and then pressed tightly by the mold, there is almost no gap on the joint surface, that is, a good water-blocking effect can be achieved without using water-blocking yarn in the conductor.
[0039] In a preferred embodiment, a water-blocking yarn is spirally wound around the outer wall of each layer of the molded wire 12 and is compressed by the outer layer of the molded wire 12 to further increase the axial water-blocking capability of the cable.
[0040] Further, such as Figure 2 As shown, the multi-layer profile lines 12 are divided into odd-numbered layers and even-numbered layers, wherein the bonding surfaces of the profile lines 12 of the odd-numbered layers do not overlap with the bonding surfaces of the profile lines 12 of the even-numbered layers.
[0041] Preferably, the bonding surfaces of the profile lines 12 of the odd-numbered layers are perpendicular to the bonding surfaces of the profile lines 12 of the even-numbered layers.
[0042] In this way, the outer layer's profiled wire 12 structure can cover the seams of the inner layer's profiled wire 12 structure, forming a maze-like gap along the radial direction of the cable, making it difficult for moisture to penetrate radially. At the same time, this structural design enables the outer layer to compress the inner layer, and will not become loose due to stress such as frequent torsion and swinging.
[0043] In an optional embodiment, the thickness of any layer of the shaped wires 12 is the same, which is conducive to large-scale production of the shaped wires 12 and can be combined to form conductors of target diameters as needed.
[0044] Furthermore, the composite braided layer 20 is covered on the outer wall of the conductor 10 , the insulating layer 30 is covered on the outer wall of the composite braided layer 20 ; and the sheath layer 40 is covered on the outer wall of the insulating layer 30 .
[0045] Among them, the composite braided layer 20 includes an inner braided layer 21, a longitudinally wrapped shielding layer 22 and an outer braided layer 23. The inner braided layer 21 includes a semi-conductive wrapping layer 212 wrapped around the outer wall of the conductor 10 and an aramid braided layer 211 woven on the outer wall of the semi-conductive wrapping layer 212. The longitudinally wrapped shielding layer 22 includes a longitudinally wrapped copper-plastic composite tape. The outer braided layer 23 includes a mixed braided layer of copper wire 232 and aramid yarn bundle 231.
[0046] In this way, by arranging the longitudinal copper-plastic composite tape between the insulating layer 30 and the conductor 10, the radial water-blocking capability of the cable can be further increased, and by designing the inner and outer braided layers, the longitudinal copper-plastic composite tape has better wrinkle resistance and torsion resistance, so as to maintain the reliable radial water-blocking capability of the longitudinal copper-plastic composite tape.
[0047] In an optional embodiment, the semi-conductive wrapping layer 212 includes a semi-conductive EPDM insulating wrapping tape with a wrapping overlap rate of 30% to 50%, the aramid braided layer 211 includes cross-woven aramid fibers, the angle between the aramid fibers and the cable axis is less than 45°, and the braiding density of the aramid braided layer 211 is 10% to 20%.
[0048] In this way, by wrapping the semi-conductive EPDM insulation tape around the conductor 10 to form a semi-conductive layer, the water-blocking capability of the conductor 10 can be improved, while providing attachment points for the aramid fiber weaving.
[0049] Further, combined Figure 4As shown, the outer braided layer 23 is a cross-braided structure, wherein the ratio of the number of copper wires 232 to the number of aramid yarn bundles 231 is 5:1 to 10:1.
[0050] Optionally, the aramid yarn is selected from high-strength, high-modulus, and wear-resistant aramid yarns, such as aramid 1414 or aramid 1313. Aramid yarns can effectively improve the tensile strength of the braided layer due to their excellent tensile strength and wear resistance.
[0051] Furthermore, the aramid yarns can be twisted together with the water-blocking yarns to form an aramid yarn bundle 231 , thereby further improving the water-blocking capability of the outer braided layer 23 .
[0052] In this way, by mixing a certain amount of aramid yarn into the copper wire braided structure, the tensile and torsional resistance of the braided structure can be increased. At the same time, combined with the aramid yarn bundles in the inner braided layer, the overall tensile performance of the cable is improved, avoiding creep of the conductor in a swinging and torsional environment, thereby avoiding loosening and deformation of the cable joints and enlargement of the conductor gaps.
[0053] Preferably, the insulating layer 30 includes a cross-linked polyethylene insulating layer, which has excellent voltage resistance and high temperature resistance, and exhibits better corrosion resistance. The sheath layer 40 includes a flame-retardant polyvinyl chloride sheath layer, which has good salt spray resistance and excellent flame retardant properties, meeting the use requirements of salt spray environments.
[0054] In combination with the above embodiments, the utility model adopts a circular core wire and a multi-layer semi-circular arc wire structure tightly pressed against the outer wall of the core wire, which can form a high-conductor structure with a high filling factor. The conductor structure is dense, which can achieve good water resistance and conductivity, and achieve good corrosion resistance. At the same time, steel wire is embedded in the conductor, and a braided layer with aramid yarn bundles is provided on the outside, so that the cable has better tensile resistance, which can increase the strength and creep resistance of the aluminum alloy conductor, and make the cable have higher reliability and service life, meeting the use requirements of offshore or offshore facilities.
[0055] 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 salt spray resistant aluminum alloy power cable, characterized in that: include: A conductor (10), the conductor (10) comprising a core wire (11) having a circular cross-section and a plurality of profiled wires (12) pressed against the outer wall of the core wire (11), each layer of the profiled wire (12) comprising a pair of profiled wire bodies that are aligned with each other, the profiled wire bodies having a cross-sectional structure of an arc plate, comprising an inner arc surface and an outer arc surface, the inner arc surface and the outer arc surface corresponding to the corresponding circles being concentric; A composite braided layer (20) wrapped around the outer wall of the conductor (10); an insulating layer (30) wrapped around the outer wall of the composite braided layer (20); a sheath layer (40) covering the outer wall of the insulating layer (30); The core wire (11) is an aluminum-clad steel structure, comprising a steel core structure (111) and an aluminum alloy structure (112), wherein the cross-sectional shape of the steel core structure (111) is circular, and the cross-sectional shape of the aluminum alloy structure (112) is annular and surrounds the outer wall of the steel core structure (111); A pair of the profiled wire bodies of each layer of the profiled wire (12) are matched with each other to form an annular structure surrounding the core wire (11) or the outer wall of the profiled wire (12) of the inner layer.
2. The salt spray resistant aluminum alloy power cable according to claim 1, characterized in that: The profile body is further provided with two side surfaces, and the two side surfaces of the profile body are located in the same plane. When a pair of profile bodies are matched with each other, the corresponding side surfaces are fitted together to form a joint surface parallel to the cable axis.
3. The salt spray resistant aluminum alloy power cable according to claim 1, characterized in that: The multiple layers of the molded lines (12) are divided into odd-numbered layers and even-numbered layers, wherein the bonding surfaces of the molded lines (12) of the odd-numbered layers do not overlap with the bonding surfaces of the molded lines (12) of the even-numbered layers.
4. The salt spray resistant aluminum alloy power cable according to claim 3, characterized in that: The bonding surfaces of the profile lines (12) of the odd-numbered layers are perpendicular to the bonding surfaces of the profile lines (12) of the even-numbered layers.
5. The salt spray resistant aluminum alloy power cable according to claim 1, characterized in that: The thickness of any layer of the profile line (12) is the same.
6. The salt spray resistant aluminum alloy power cable according to claim 1, characterized in that: The diameter of the core wire (11) is 2 to 3 mm, and the diameter ratio of the steel core structure (111) to the aluminum alloy structure (112) is 1:2 to 1:
3.
7. The salt spray resistant aluminum alloy power cable according to any one of claims 1 to 6, characterized in that: The composite braided layer (20) comprises an inner braided layer (21), a longitudinally wrapped shielding layer (22), and an outer braided layer (23); the inner braided layer (21) comprises a semi-conductive wrapping layer (212) wrapped around the outer wall of the conductor (10) and an aramid braided layer (211) braided on the outer wall of the semi-conductive wrapping layer (212); the longitudinally wrapped shielding layer (22) comprises a longitudinally wrapped copper-plastic composite tape; and the outer braided layer (23) comprises a mixed braided layer of copper wires (232) and aramid filament bundles (231).
8. The salt spray resistant aluminum alloy power cable according to claim 7, characterized in that: The semi-conductive wrapping layer (212) comprises a semi-conductive EPDM insulating wrapping tape with a wrapping overlap rate of 30% to 50%, the aramid braided layer (211) comprises cross-woven aramid fibers, the angle between the aramid fibers and the cable axis is less than 45°, and the braiding density of the aramid braided layer (211) is 10% to 20%.
9. The salt spray resistant aluminum alloy power cable according to claim 7, characterized in that: The outer braided layer (23) is a cross-braided structure, wherein the ratio of the number of copper wires (232) to the number of aramid fiber bundles (231) is 5:1 to 10:
1.
10. The salt spray resistant aluminum alloy power cable according to claim 1, characterized in that: The insulating layer (30) comprises a cross-linked polyethylene insulating layer, and the sheath layer (40) comprises a polyvinyl chloride sheath layer.