Impact-resistant and distortion-resistant outdoor polyethylene power cable

Abstract

The utility model discloses an impact-resistant anti-distortion outdoor polyethylene power cable, which relates to the technical field of cables and comprises a cable core, four annularly distributed wire cores are arranged in the cable core, and each wire core is composed of an inner conductor, an outer conductor, a heat conduction enhancement layer, an inner enhancement layer and an inner insulating layer. A shielding combination layer is arranged outside the wrapping layer, the shielding combination layer is composed of a high-conductivity metal film layer, a nanometer shielding layer and a protective coating, an anti-impact combination layer is arranged outside the shielding combination layer, and the anti-impact combination layer is composed of an impact dispersion layer and an energy absorption layer. The power cable comprises an anti-impact combined layer, an anti-distortion combined layer is arranged outside the anti-impact combined layer, the anti-distortion combined layer is composed of a core layer and an elastic buffer layer, an outer sheath is arranged outside the anti-distortion combined layer, and the outer sheath is composed of a strengthening layer, a blocking layer and an outer protection layer. And meanwhile, the maintenance is inconvenient.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, specifically to an impact-resistant and torsion-resistant outdoor polyethylene power cable. Background Technology

[0002] Power cables are important equipment used for transmitting and distributing electrical energy. They are typically composed of conductors, insulation layers, sheathing layers, and possibly shielding layers. They have excellent conductivity, insulation properties, and mechanical strength, and can safely and efficiently transmit electricity from power plants or substations to users. They are widely used in urban power grids, industrial plants, underground projects, and various power systems, and are an indispensable part of modern society's infrastructure.

[0003] For example, the Chinese authorized patent CN118969369A, entitled "A Mobile Metal-Shielded Monitoring Rubber-Sheathed Flexible Cable for Coal Mines," includes a cable core and, sequentially arranged outside the cable core, an inner sheath, a monitoring layer, a reinforcing layer, an outer sheath layer, an anti-torsion marking strip, and a permanent embossed marking. The outer sheath layer, the anti-torsion marking strip, and the permanent embossed marking are manufactured using a one-piece molding process. The reinforcing layer includes a columnar spiral structure formed by a reinforcing strip spirally wrapped around the monitoring layer. Several protrusions are evenly formed on the spiral edge of the columnar spiral structure, and the protrusions are formed by the reinforcing strip continuously bending in the radial direction of the columnar spiral structure. Since the anti-torsion marking strip is embedded in the surface of the outer sheath layer, the anti-torsion marking strip can be integrated with the cable.

[0004] The existing technologies described above are susceptible to damage from the installation environment, especially in harsh environments, where the cable body is easily subjected to impact and torsion, resulting in a decrease in service life. At the same time, it is difficult to find the pressure points during cable maintenance, which affects maintenance work. Therefore, they do not meet the current requirements. In response, we propose an impact-resistant and torsion-resistant outdoor polyethylene power cable. Utility Model Content

[0005] The purpose of this invention is to provide an impact-resistant and torsion-resistant outdoor polyethylene power cable to solve the problems mentioned in the background art, such as poor impact and torsion resistance of power cables and inconvenience in maintenance.

[0006] To achieve the above objectives, this utility model provides the following technical solution: an impact-resistant and torsion-resistant outdoor polyethylene power cable, comprising a cable core, wherein the cable core has four annularly distributed wire cores inside, the wire cores being twisted together, the wire core being composed of an inner conductor, an outer conductor, a thermally conductive reinforcing layer, an inner reinforcing layer, and an inner insulation layer, the cable core being wrapped with a wrapping layer, the wrapping layer being provided with a shielding combination layer outside the wrapping layer, the shielding combination layer being composed of a highly conductive metal thin film layer, a nano-shielding layer, and a protective coating, the shielding combination layer being provided with an impact-resistant combination layer outside the shielding combination layer, the impact-resistant combination layer being composed of an impact dispersion layer and an energy absorption layer, the impact-resistant combination layer being provided with an anti-torsion combination layer outside the impact-resistant combination layer, the anti-torsion combination layer being composed of a core layer and an elastic buffer layer, the anti-torsion combination layer being provided with an outer sheath outside the anti-torsion combination layer, the outer sheath being composed of a reinforcing layer, a barrier layer, and an outer protective layer.

[0007] Preferably, the inner conductor and the outer conductor are made of multiple strands of nanoscale copper-silver alloy twisted together, with the outer conductor located outside the inner conductor and having a larger diameter than the inner conductor.

[0008] Preferably, the thermally conductive reinforcement layer is coated on the outer wall of the outer conductor using chemical vapor deposition technology, the inner reinforcement layer is tightly wrapped around the outer wall of the thermally conductive reinforcement layer in a cross-woven manner, and the inner insulation layer is coated on the outer wall of the inner reinforcement layer using multilayer co-extrusion technology.

[0009] Preferably, the highly conductive metal thin film layer is stacked in multiple layers on the outer wall of the wrapping layer, the nano-shielding layer is fixed to the outer wall of the highly conductive metal thin film layer by an adhesive, and the protective coating is applied to the outer wall of the nano-shielding layer.

[0010] Preferably, the impact dispersion layer has a multi-layered wave-shaped structure, and the impact dispersion layer and the shielding combination layer are fixed together by an adhesive. The energy absorption layer is fixed together with the impact dispersion layer by an adhesive, and the energy absorption layer and the core layer are connected by an interface reinforcement layer.

[0011] Preferably, the energy absorption layer has elastic support columns embedded inside, arranged along the cable axis.

[0012] Preferably, the elastic buffer layer has a multi-layer structure, and the elastic buffer layer is fixed to the core layer by an adhesive, while the elastic buffer layer is fixed to the reinforcing layer by a high-viscosity epoxy resin.

[0013] Preferably, the barrier layer is wrapped around the outer wall of the reinforcing layer by an extrusion process, and the outer protective layer is wrapped around the outer wall of the barrier layer by an extrusion process.

[0014] Preferably, the outer wall of the outer protective layer is coated with a pressure color-changing layer, and wear-resistant protrusions are adhered and fixed to the outer wall of the pressure color-changing layer.

[0015] Preferably, the composite material of the nano-shielding layer has a multi-layered microporous structure embedded in it.

[0016] Compared with the prior art, the beneficial effects of this utility model are:

[0017] 1. This utility model optimizes the internal structure of the conductor core. The nano-level copper-silver alloy conductor has lower resistivity and better corrosion resistance, which can significantly improve the conductivity and stability of the cable. The introduction of the graphene composite layer effectively improves the thermal conductivity of the cable, reduces the operating temperature of the cable, and improves the current carrying capacity and long-term stability of the cable. The addition of aramid fiber significantly improves the tensile strength, torsion resistance and impact resistance of the cable, enabling the cable to maintain stable performance in harsh environments. The excellent insulation performance and mechanical strength design effectively prevent short circuits, leakage and other safety hazards caused by external damage or overheating of the cable, ensuring the safety of power transmission.

[0018] 2. This utility model features an anti-torsion composite layer with aramid fiber braided tape as the core support layer, which effectively resists torsional deformation and protects the internal structure of the cable from damage. The elastic buffer layer provides buffering and energy absorption during torsion while maintaining the cable's flexibility, facilitating installation and bending. The interface adhesive layer firmly bonds the anti-torsion layer to the outer sheath, enhancing the overall stability of the cable and preventing delamination or peeling during torsion. Although the anti-torsion layer primarily focuses on mechanical properties, a reasonable structural design ensures that its impact on the cable's conductivity is minimized, maintaining the cable's high-efficiency transmission capability.

[0019] 3. This utility model, through the combined design of an impact-resistant composite layer, an impact dispersion layer, and an energy absorption layer, can efficiently absorb and disperse external impact energy, protecting the internal structure of the cable from damage. The design of microporous foam material and elastic support columns ensures that the impact-resistant layer maintains high impact absorption while also preserving the cable's flexibility, facilitating installation and bending. The use of an interface reinforcement layer significantly improves the bonding strength between the impact-resistant layer and the anti-torsion composite layer, preventing delamination or peeling and enhancing the overall stability of the cable. By selecting lightweight and high-performance materials and optimizing the structural design, the impact-resistant layer is made lightweight, reducing the overall weight of the cable and facilitating transportation and installation. Attached Figure Description

[0020] Figure 1 This is a perspective view of the entire utility model;

[0021] Figure 2 This is a schematic diagram of the overall cross-sectional structure of this utility model;

[0022] Figure 3 This is a three-dimensional view of the wire core of this utility model;

[0023] Figure 4 This is a perspective view of the shielding composite layer of this utility model;

[0024] Figure 5 This is a perspective view of the impact-resistant composite layer of this utility model;

[0025] Figure 6 This is a perspective view of the anti-torsion composite layer of this utility model;

[0026] Figure 7 This is a perspective view of the outer sheath of this utility model.

[0027] In the diagram: 1. Core; 11. Inner conductor; 12. Outer conductor; 13. Thermally conductive reinforcement layer; 14. Inner reinforcement layer; 15. Inner insulation layer; 2. Wrapping layer; 3. Shielding composite layer; 31. Highly conductive metal thin film layer; 32. Nano-shielding layer; 33. Protective coating; 4. Impact-resistant composite layer; 41. Impact dispersion layer; 42. Energy absorption layer; 43. Elastic support column; 5. Torsion-resistant composite layer; 51. Core layer; 52. Elastic buffer layer; 53. Interface bonding layer; 6. Outer sheath; 61. Reinforcing layer; 62. Barrier layer; 63. Outer protective layer; 64. Pressure color-changing layer; 7. Wear-resistant protrusion. Detailed Implementation

[0028] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0029] Please see Figure 1 , Figure 2 and Figure 3 This utility model provides an embodiment of an impact-resistant and torsion-resistant outdoor polyethylene power cable, comprising a cable core. The cable core has four annularly distributed wire cores 1 inside, which are twisted together. Each wire core 1 consists of an inner conductor 11, an outer conductor 12, a thermally conductive reinforcing layer 13, an inner reinforcing layer 14, and an inner insulation layer 15. The cable core is wrapped with a wrapping layer 2. The inner conductor 11 and the outer conductor 12 are made of multiple strands of nanoscale copper-silver alloy twisted together. The outer conductor 12 is located outside the inner conductor 11, and the diameter of the outer conductor 12 is larger than that of the inner conductor 11. The thermally conductive reinforcing layer 13 is coated on the outer wall of the outer conductor 12 by chemical vapor deposition technology. The inner reinforcing layer 14 is tightly wrapped around the outer wall of the thermally conductive reinforcing layer 13 by cross-braiding. The inner insulation layer 15 is wrapped on the outer wall of the inner reinforcing layer 14 by multi-layer co-extrusion technology.

[0030] The conductor uses a nano-scale copper-silver alloy as the conductor material. This alloy not only possesses the high conductivity of copper but also incorporates the excellent corrosion resistance and antibacterial properties of silver, maintaining stable conductivity even in extreme environments. It is designed with a multi-layer stranded structure, with a tightly stranded fine copper-silver alloy wire as the inner layer and a thicker copper-silver alloy wire spirally wrapped on the outer layer, forming a "core-shell" structure. This design enhances both the mechanical strength of the conductor and improves the uniformity of current transmission. The thermally conductive reinforcement layer 13 adds a micro-nano structured graphene composite layer to the outer layer of the conductor. Graphene, with its extremely high thermal conductivity, effectively and rapidly conducts the heat generated by the conductor to the outside, reducing the cable's operating temperature and improving its current-carrying capacity and stability. The graphene composite layer is uniformly coated onto the conductor surface using chemical vapor deposition technology, forming a thin, continuous, and highly conductive coating while maintaining the cable's flexibility. The inner reinforcement layer 14 introduces high-strength aramid fibers as a mechanical reinforcement layer, possessing… It possesses extremely high tensile strength and toughness, significantly enhancing the cable's tensile, torsional, and impact resistance. Aramid fibers are tightly wrapped around the thermally conductive reinforcement layer in a cross-woven manner, forming a robust protective layer while maintaining the cable's flexibility. The inner insulation layer 15 is made of polyimide, exhibiting excellent electrical insulation properties, thermal stability, and chemical corrosion resistance. It effectively isolates the conductor from the external environment, ensuring the cable's safe operation. A multi-layer co-extrusion technology is used to form a dense insulation structure. Furthermore, additives such as anti-aging agents and UV stabilizers are incorporated into the insulation layer to extend the cable's service life.

[0031] Please see Figure 1 , Figure 2 and Figure 4 The outer side of the wrapping layer 2 is provided with a shielding combination layer 3, which is composed of a high conductivity metal thin film layer 31, a nano shielding layer 32 and a protective coating 33. The high conductivity metal thin film layer 31 is stacked in multiple layers on the outer wall of the wrapping layer 2. The nano shielding layer 32 is fixed to the outer wall of the high conductivity metal thin film layer 31 by an adhesive. The protective coating 33 is coated on the outer wall of the nano shielding layer 32. The composite material of the nano shielding layer 32 has a multi-layer microporous structure embedded in it.

[0032] The highly conductive metal thin film layer 31 is made of aluminum foil, which has excellent conductivity and can quickly conduct and disperse electromagnetic waves, reducing signal interference. It is multi-layered to increase the conductive path and improve shielding effectiveness. Simultaneously, the thin and lightweight design of the film helps reduce the overall weight of the cable. The nano-shielding layer 32 is made of a polymer-based composite material reinforced with nanoparticles (such as nano-graphite, nano-silver, or nano-ferrite). It not only has excellent conductivity and shielding effectiveness, but also improves the mechanical properties and corrosion resistance of the material through the addition of nanoparticles. The multi-layered microporous structure can absorb and disperse electromagnetic waves, further enhancing the shielding effect. At the same time, the microporous structure also helps reduce the weight of the cable. The protective coating 33 is made of polyethylene, increasing the cable's abrasion resistance and tear resistance.

[0033] Please see Figure 1 , Figure 2 and Figure 5 An impact-resistant composite layer 4 is provided on the outside of the shielding composite layer 3. The impact-resistant composite layer 4 is composed of an impact dispersion layer 41 and an energy absorption layer 42. The impact dispersion layer 41 has a multi-layer corrugated structure and is fixed to the shielding composite layer 3 by an adhesive. The energy absorption layer 42 is fixed to the impact dispersion layer 41 by an adhesive. The energy absorption layer 42 is connected to the core layer 51 by an interface reinforcement layer. Elastic support columns 43 arranged along the cable axis are embedded inside the energy absorption layer 42.

[0034] The impact dispersion layer 41 is made of nanoparticle-reinforced polyurethane, which can quickly disperse stress and reduce local damage when subjected to impact. It is designed as a multi-layered wave shape. This structure can not only increase the surface area of ​​the material and improve the impact absorption efficiency, but also absorb and disperse energy through structural deformation when subjected to impact. The energy absorption layer 42 is made of microporous polyethylene, which has excellent energy absorption capacity and resilience. The elastic support column 43 can provide additional support and cushioning when subjected to impact, while maintaining the flexibility of the cable. The interface reinforcement layer uses a high-viscosity thermoplastic elastomer and is located between the impact-resistant layer and the anti-torsion composite layer. Through a special bonding process, the impact-resistant layer is firmly bonded to the anti-torsion composite layer, while enhancing the interface strength between the two layers to prevent delamination or peeling when subjected to impact.

[0035] Please see Figure 1 , Figure 2 and Figure 6 An anti-torsion composite layer 5 is provided on the outside of the impact-resistant composite layer 4. The anti-torsion composite layer 5 consists of a core layer 51 and an elastic buffer layer 52. The elastic buffer layer 52 has a multi-layer structure and is fixed to the core layer 51 by an adhesive. The elastic buffer layer 52 is fixed to the reinforcing layer 61 by a high-viscosity epoxy resin.

[0036] The core layer 51 is a carbon fiber braided tape, which has excellent mechanical properties and fatigue resistance, and can withstand large torque and bending stress. The braided tape is tightly wound in a spiral shape around the outer wall of the cable core, forming a solid support layer to enhance its torsion resistance. The elastic buffer layer 52 is an ethylene-vinyl acetate copolymer foam layer with good buffering performance and energy absorption characteristics. It can absorb impact energy during torsion and protect the internal structure of the cable. The elastic buffer layer can be designed as a multi-layer structure, with each layer connected by tiny elastic connection points, which maintains elasticity and enhances the energy absorption effect. The interface adhesive layer 53 is set between the elastic buffer layer and the outer sheath. It uses high-viscosity epoxy resin to firmly bond the anti-torsion layer to the outer sheath, preventing delamination or peeling during torsion. It not only plays an adhesive role, but also transmits stress to a certain extent, allowing the outer sheath to participate in the anti-torsion process and enhancing the overall torsion resistance of the cable.

[0037] Please see Figure 1 , Figure 2 and Figure 7 The outer sheath 6 is provided on the outside of the anti-torsion composite layer 5. The outer sheath 6 is composed of a reinforcing layer 61, a barrier layer 62 and an outer sheath 63. The barrier layer 62 is wrapped on the outer wall of the reinforcing layer 61 by an extrusion process, and the outer sheath 63 is wrapped on the outer wall of the barrier layer 62 by an extrusion process.

[0038] The reinforcing layer 61 is made of polyester fiber, which has excellent mechanical properties and fatigue resistance, and can enhance the strength and wear resistance of the outer sheath. The multi-layer cross-woven mesh structure increases the tear resistance and overall stability of the outer sheath. The barrier layer 62 is made of high-density polyethylene, which has good impermeability and barrier properties, and can prevent the intrusion of moisture, oxygen and other chemicals, protecting the internal structure of the cable.

[0039] A thin layer of nanoscale barrier material, such as nano-alumina, is added to the middle barrier layer 62 to further improve barrier performance. The outer sheath 63 is made of weather-resistant and UV-resistant polyvinyl chloride, which can resist the erosion of harsh weather and ultraviolet rays, extending the cable's service life. Anti-aging agents and light stabilizers are added to the outer protective layer to improve the material's weather resistance and UV resistance. At the same time, the outer surface can be designed with a rough or non-slip texture to increase the cable's grip and safety.

[0040] Please see Figure 1 and Figure 7The outer sheath 63 is coated with a pressure-sensitive color-changing layer 64, and wear-resistant protrusions 7 are adhered and fixed to the outer wall of the pressure-sensitive color-changing layer 64. Pressure-sensitive color-changing material is a special functional material whose color changes with external pressure. Under pressure, the structure or electronic state of the pressure-sensitive color-changing material changes, causing its color to change. Therefore, when the cable is subjected to impact or pressure, the pressure-sensitive color-changing material at the impact point will change color. By observing the color change, the impacted or pressured area can be quickly located, facilitating timely troubleshooting and repair. Furthermore, during installation, if bending forces cause the color of the material in the pressure-sensitive color-changing layer to change, installation operators can determine the bending stress of the cable in real time based on the color change, thereby reducing damage to the cable due to excessive bending forces. This not only improves the safety and reliability of the cable but also reduces maintenance and troubleshooting costs. By observing color changes, problem areas can be quickly located, allowing for timely repair and handling, avoiding safety accidents and economic losses caused by cable faults.

[0041] It will be apparent to those skilled in the art that this invention is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of this invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. An impact-resistant and torsion-resistant outdoor polyethylene power cable, comprising a cable core, characterized in that: The cable core has four annularly distributed cores (1) inside, which are twisted together. Each core (1) consists of an inner conductor (11), an outer conductor (12), a thermally conductive reinforcing layer (13), an inner reinforcing layer (14), and an inner insulation layer (15). The cable core is wrapped with a wrapping layer (2), and a shielding combination layer (3) is provided outside the wrapping layer (2). The shielding combination layer (3) consists of a highly conductive metal thin film layer (31), a nano-shielding layer (32), and a protective coating (33). An impact-resistant composite layer (4) is provided on the outside of the shielding composite layer (3). The impact-resistant composite layer (4) is composed of an impact dispersion layer (41) and an energy absorption layer (42). An anti-torsion composite layer (5) is provided on the outside of the impact-resistant composite layer (4). The anti-torsion composite layer (5) is composed of a core layer (51) and an elastic buffer layer (52). An outer sheath (6) is provided on the outside of the anti-torsion composite layer (5). The outer sheath (6) is composed of a reinforcing layer (61), a barrier layer (62), and an outer protective layer (63).

2. The impact-resistant and torsion-resistant outdoor polyethylene power cable according to claim 1, characterized in that: The inner conductor (11) and the outer conductor (12) are made of multiple strands of nanoscale copper-silver alloy. The outer conductor (12) is located outside the inner conductor (11), and the diameter of the outer conductor (12) is larger than that of the inner conductor (11).

3. The impact-resistant and torsion-resistant outdoor polyethylene power cable according to claim 2, characterized in that: The thermally conductive reinforcement layer (13) is coated on the outer wall of the outer conductor (12) by chemical vapor deposition. The inner reinforcement layer (14) is tightly wrapped around the outer wall of the thermally conductive reinforcement layer (13) in a cross-woven manner. The inner insulation layer (15) is coated on the outer wall of the inner reinforcement layer (14) by multi-layer co-extrusion technology.

4. The impact-resistant and torsion-resistant outdoor polyethylene power cable according to claim 1, characterized in that: The highly conductive metal thin film layer (31) is stacked in multiple layers on the outer wall of the wrapping layer (2), the nano shielding layer (32) is fixed to the outer wall of the highly conductive metal thin film layer (31) by an adhesive, and the protective coating (33) is coated on the outer wall of the nano shielding layer (32).

5. The impact-resistant and torsion-resistant outdoor polyethylene power cable according to claim 1, characterized in that: The impact dispersion layer (41) is a multi-layered wave-shaped structure, and the impact dispersion layer (41) and the shielding combination layer (3) are fixed by an adhesive. The energy absorption layer (42) is fixed to the impact dispersion layer (41) by an adhesive. The energy absorption layer (42) and the core layer (51) are connected by an interface enhancement layer (53).

6. The impact-resistant and torsion-resistant outdoor polyethylene power cable according to claim 5, characterized in that: The energy absorption layer (42) has elastic support columns (43) embedded inside, arranged along the cable axis.

7. The impact-resistant and torsion-resistant outdoor polyethylene power cable according to claim 1, characterized in that: The elastic buffer layer (52) has a multi-layer structure, and the elastic buffer layer (52) and the core layer (51) are fixed by an adhesive, and the elastic buffer layer (52) and the reinforcing layer (61) are fixed by a high-viscosity epoxy resin.

8. The impact-resistant and torsion-resistant outdoor polyethylene power cable according to claim 1, characterized in that: The barrier layer (62) is wrapped on the outer wall of the reinforcing layer (61) by an extrusion process, and the outer protective layer (63) is wrapped on the outer wall of the barrier layer (62) by an extrusion process.

9. The impact-resistant and torsion-resistant outdoor polyethylene power cable according to claim 8, characterized in that: The outer wall of the outer protective layer (63) is coated with a pressure color-changing layer (64), and wear-resistant protrusions (7) are adhered and fixed to the outer wall of the pressure color-changing layer (64).

10. The impact-resistant and torsion-resistant outdoor polyethylene power cable according to claim 4, characterized in that: The composite material of the nano-shielding layer (32) has a multi-layered microporous structure embedded in it.

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