Halogen-free low-smoke low-toxicity long-life light-weight power cable

Abstract

The utility model relates to the technical field of characteristic cables, in particular to a halogen-free low-smoke low-toxicity long-service-life light-weight power cable, which comprises a cable core formed by a plurality of conductors. A first insulating layer, a second insulating layer and a third insulating layer are sequentially coated outside the conductor; the flame-retardant layer is overlapped and wrapped outside the cable core, and a flame-retardant filler is filled in a gap between the cable cores in the flame-retardant layer; an inner protective layer; the flame-retardant layer is extruded and molded outside the flame-retardant layer; an armor layer; the composite braid wraps the outer part of the inner protection layer; and the outer protection layer is extruded and formed outside the armor layer. The cable has excellent electrical properties and mechanical properties such as aging resistance, bending resistance, hot oil resistance, high temperature resistance, high radiation resistance, long service life, high flame retardance, tear resistance, strong electromagnetic interference resistance, light weight, low smoke, no halogen, low toxicity and the like, and can meet requirements of 1E-level special use environments in nuclear power stations on ships and warships.

Description

Technical Field

[0001] This utility model relates to the field of characteristic cable technology, specifically to a halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable. Background Technology

[0002] Marine power cables are specifically designed for use in floating structures such as warships, river and sea vessels, and offshore oil platforms, for transmitting power and energy to equipment, instruments, and meters. These cables must possess the following characteristics: superior electrical performance, aging resistance, bending resistance, long lifespan, tear strength, heat and oil resistance, high flame retardancy, strong fire resistance, low smoke and halogen-free properties, and low toxicity, to ensure excellent electrical and mechanical properties even in harsh environments.

[0003] However, there is currently a shortage of shipboard nuclear power plant power cables for power transmission on the market, with the main reliance on cables from civilian nuclear power plants as substitutes. Although these cables can meet the harsh environmental conditions of nuclear power plants, such as high temperature, high radiation, and strong electromagnetic interference, their performance is difficult to meet the requirements in shipboard applications, such as confined space, limited load capacity, susceptibility to seawater and oil corrosion, and exposure to intense sunlight.

[0004] Furthermore, advancements in aluminum alloy conductor manufacturing processes in recent years have brought the electrical and mechanical properties of aluminum alloy conductors close to those of copper conductors, while their weight is only one-third that of copper. Therefore, high-strength, high-conductivity aluminum alloy conductors can serve as an excellent alternative to copper conductors.

[0005] To address the aforementioned issues, we propose a Class 1E halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable for use in shipboard nuclear power plants. Utility Model Content

[0006] To address the aforementioned issues, a halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable is provided, comprising: a cable core composed of several conductors; the conductors are sequentially covered by a first insulation layer, a second insulation layer, and a third insulation layer; a flame-retardant layer, overlapping and wrapped around the outside of the cable core, with flame-retardant filler filling the gaps between the cable cores within the flame-retardant layer; an inner protective layer; extruded and formed on the outside of the flame-retardant layer; an armor layer; a composite braided layer covering the outside of the inner protective layer; and an outer protective layer, extruded and formed on the outside of the armor layer.

[0007] Preferably, the conductor is formed by stranding and re-stretching aluminum alloy monofilaments in the same direction.

[0008] Preferably, the first insulating layer is an irradiated cross-linked polyethylene insulating layer, and the second insulating layer is an irradiated cross-linked polyolefin insulating layer.

[0009] Preferably, the first insulating layer and the second insulating layer are formed by double-layer co-extrusion in one step.

[0010] Preferably, the third insulating layer is formed by overlapping and wrapping polyimide insulating tape.

[0011] Preferably, the flame-retardant layer is formed by wrapping a low-smoke, halogen-free, high-flame-retardant tape.

[0012] Preferably, the flame-retardant filler is a low-smoke, halogen-free, high-flame-retardant filler.

[0013] Preferably, the inner protective layer is extruded from a thermosetting, low-smoke, halogen-free, flame-retardant polyolefin sheath material.

[0014] Preferably, the armor layer is made of a composite weave of tin-plated copper wire and aramid fiber.

[0015] Preferably, the outer protective layer is extruded from a thermosetting, low-smoke, halogen-free, flame-retardant polyolefin sheath material.

[0016] Compared with the prior art, the advantages of this utility model are: it has excellent electrical and mechanical properties such as aging resistance, bending resistance, hot oil resistance, high temperature resistance, high radiation resistance, long life, high flame retardancy, tear resistance, strong electromagnetic interference resistance, lightweight, low smoke, halogen-free, and low toxicity, which can meet the special 1E class operating environment in nuclear power plants on ships. Attached Figure Description

[0017] Figure 1 This is a structural schematic diagram of a halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable according to this utility model.

[0018] The numbers in the diagram are: 1. Conductor; 2. First insulation layer; 3. Second insulation layer; 4. Third insulation layer; 5. Flame-retardant filler; 6. Flame-retardant layer; 7. Inner protective layer; 8. Armor layer; 9. Outer protective layer. Detailed Implementation

[0019] To further understand the features, technical means, and specific objectives and functions achieved by this utility model, the following detailed description of this utility model is provided in conjunction with the accompanying drawings and specific embodiments.

[0020] See Figure 1 The halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable shown includes: a cable core, which is composed of several conductors 1; the conductors 1 are sequentially covered by a first insulation layer 2, a second insulation layer 3, and a third insulation layer 4; a flame-retardant layer 6, which is overlapped and wrapped around the outside of the cable core, and flame-retardant filler 5 is filled in the gaps between the cable cores within the flame-retardant layer 6; an inner protective layer 7; which is extruded and formed on the outside of the flame-retardant layer 6; an armor layer 8; which is composite braided and wrapped around the outside of the inner protective layer 7; and an outer protective layer 9, which is extruded and formed on the outside of the armor layer 8.

[0021] The conductor 1 is formed by stranding and re-stretching aluminum alloy monofilaments in the same direction. The first insulation layer 2 is an irradiated cross-linked polyethylene insulation layer, and the second insulation layer 3 is an irradiated cross-linked polyolefin insulation layer. The first insulation layer 2 and the second insulation layer 3 are formed by double-layer co-extrusion in one step. The third insulation layer 4 is formed by overlapping and wrapping polyimide insulating tape. The flame retardant layer 6 is formed by wrapping low-smoke halogen-free high flame retardant tape. The flame retardant filler 5 is a low-smoke halogen-free high flame retardant filler 5. The inner protective layer 7 is extruded from thermosetting low-smoke halogen-free flame retardant polyolefin sheath material. The armor layer 8 is woven from tin-plated copper wire and aramid fiber composite, with a weaving density of not less than 95%. The outer protective layer 9 is extruded from thermosetting low-smoke halogen-free flame retardant polyolefin sheath material.

[0022] Conductor 1 employs a Category 5 soft-structure design, using high-strength, high-conductivity aluminum alloy monofilament as the main material. It undergoes unidirectional stranding and re-stretching processes using specialized bundled and twisted equipment. Compared to conventional reverse-layer structures, this design gives conductor 1 superior bending performance and a smaller outer diameter. Furthermore, compared to copper conductors, aluminum alloy conductor 1 is two-thirds lighter.

[0023] The armor layer 8 is made of a composite braid of tin-plated copper wire and aramid fiber. Aramid, as a new type of high-tech synthetic fiber, possesses superior physical properties: its strength is 5-6 times that of steel wire, its modulus is 2-3 times that of steel wire or glass fiber, its toughness is twice that of steel wire, while its weight is only about 1 / 5 that of steel wire. Aramid will not decompose or melt at a high temperature of 560℃. This characteristic gives the cable ultra-high strength, high modulus, and excellent properties such as high temperature resistance, acid and alkali resistance, further reducing the overall weight of the cable. At the same time, the tin-plated copper wire braid also acts as a shield, effectively improving the cable's resistance to strong electromagnetic interference.

[0024] In terms of insulation layer design, the first insulation layer 2 and the second insulation layer 3 adopt a double-layer co-extrusion technology of irradiated cross-linked polyethylene and irradiated cross-linked polyolefin. In addition, a third insulation layer 4 is formed by overlapping and wrapping polyimide insulation tape. The gaps between the cable cores are filled with low-smoke halogen-free high flame-retardant filler 5.

[0025] Regarding the protective layers, both the inner protective layer 7 and the outer protective layer 9 are extruded from thermosetting low-smoke halogen-free flame-retardant polyolefin. This design not only gives the cable excellent electrical and mechanical properties but also significantly improves its resistance to aging, bending, hot oil, high temperatures, high radiation, long lifespan, high flame retardancy, tear resistance, and strong electromagnetic interference. Simultaneously, the cable also possesses environmentally friendly characteristics such as low smoke, halogen-free, and low toxicity to meet the special environmental requirements of nuclear power plants on ships.

[0026] The above embodiments only illustrate one or more implementations of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this utility model. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the appended claims.

Claims

1. A halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable, characterized in that, include: The cable core is composed of a plurality of conductors (1); the conductors (1) are covered in sequence by a first insulating layer (2), a second insulating layer (3) and a third insulating layer (4); A flame-retardant layer (6) is wrapped around the outside of the cable core, and flame-retardant filler (5) is filled in the gap between the cable cores within the flame-retardant layer (6). Inner protective layer (7); extruded onto the outside of flame retardant layer (6); Armor layer (8); composite braided covering the outside of the inner protective layer (7); The outer protective layer (9) is extruded and formed outside the armor layer (8).

2. The halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable according to claim 1, characterized in that, The conductor (1) is made of aluminum alloy monofilaments twisted together in the same direction and then twisted again.

3. The halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable according to claim 1, characterized in that, The first insulating layer (2) is an irradiated cross-linked polyethylene insulating layer, and the second insulating layer (3) is an irradiated cross-linked polyolefin insulating layer.

4. The halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable according to claim 3, characterized in that, The first insulating layer (2) and the second insulating layer (3) are formed by double-layer co-extrusion in one step.

5. The halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable according to claim 1, characterized in that, The third insulating layer (4) is formed by overlapping and wrapping polyimide insulating tape.

6. A halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable according to any one of claims 1-5, characterized in that, The flame-retardant layer (6) is formed by wrapping a low-smoke, halogen-free, high flame-retardant strip.

7. A halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable according to claim 6, characterized in that, The flame-retardant filler (5) is a low-smoke, halogen-free, high flame-retardant filler (5).

8. The halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable according to claim 7, characterized in that, The inner protective layer (7) is extruded from thermosetting low-smoke halogen-free flame-retardant polyolefin sheath material.

9. A halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable according to claim 8, characterized in that, The armor layer (8) is made of tin-plated copper wire and aramid fiber composite braiding.

10. A halogen-free, low-smoke, low-toxicity, long-life, lightweight power cable according to claim 9, characterized in that, The outer protective layer (9) is extruded from thermosetting low-smoke halogen-free flame-retardant polyolefin sheath material.

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