Flexible power cable

Abstract

The utility model provides a flexible power cable, which comprises a hollow outer protective layer and a plurality of leads arranged in the outer protective layer, and further comprises a supporting net, the supporting net is of a tubular structure, and the supporting net is provided with a plurality of net holes; the supporting net is embedded in the outer protection layer, and the supporting net and the outer protection layer are coaxially arranged. The flexible power cable not only has good bending resistance, but also is simple in structure and convenient to produce and manufacture, and the cost can be reduced.

Description

Technical Field

[0001] This utility model relates to the field of cable structure technology, and in particular to a flexible power cable. Background Technology

[0002] Flexible power cables are a common type of cable widely used in power transmission, data transmission, and communication control. Currently, commonly used flexible power cables generally consist of an outer protective layer (armor layer) and multiple core wires within the outer protective layer. In some applications, flexible power cables need to be bent, folded, or twisted during use or storage. To improve their bending resistance, some flexible power cables incorporate numerous reinforcing structures. For example, to enhance bending resistance, patent CN219085688U discloses a power cable with structures including an elastic cotton rope, an inner protective sheath, bending springs, flexible filler cotton, a protective layer, and a rubber protective shell. While this type of flexible power cable exhibits good bending resistance, its complex structure makes it difficult to manufacture and results in higher costs. Utility Model Content

[0003] The purpose of this invention is to provide a flexible power cable that not only has good bending resistance, but also has a simple structure, is easy to manufacture, and can reduce costs.

[0004] This utility model provides a flexible power cable, including a hollow outer protective layer and multiple conductors disposed within the outer protective layer. The flexible power cable also includes a support mesh, which is a tubular structure with multiple mesh holes. The support mesh is embedded in the outer protective layer and is coaxially arranged with the outer protective layer.

[0005] In one possible implementation, the support mesh is made of a non-metallic material, and the mesh size of the support mesh is 50-200 mesh.

[0006] In one possible implementation, the support mesh is made of polypropylene, nylon, or aramid.

[0007] In one possible implementation, the support mesh is made of metal and has a mesh size of 5-50.

[0008] In one feasible approach, the support mesh is made of stainless steel or nickel-plated copper.

[0009] In one possible implementation, the support mesh is a single-layer structure, and the distance between the support mesh and the outer surface of the outer protective layer is greater than the distance between the support mesh and the inner surface of the outer protective layer.

[0010] In one possible implementation, the support mesh is a multi-layered structure; the number of support meshes is at least two, the diameters of the at least two support meshes are different, the at least two support meshes are coaxially arranged, and the at least two support meshes are spaced apart within the outer protective layer.

[0011] In one feasible manner, the mesh count of the outer support mesh is greater than the mesh count of the inner support mesh.

[0012] In one possible implementation, the flexible power cable further includes an insulation layer that wraps around the exterior of the plurality of conductors, the insulation layer being located between the conductors and the outer protective layer.

[0013] In one feasible embodiment, a flexible central tube is provided at the center of the outer protective layer, and multiple wires are evenly arranged around the flexible central tube in the circumferential direction.

[0014] The flexible power cable provided by this utility model features a support mesh embedded within the outer protective layer. This support mesh acts as the skeleton of the outer protective layer. Due to its excellent structural strength and flexibility, embedding the support mesh within the outer protective layer enhances these properties, making it less prone to breakage during bending and thus improving the bending resistance of the flexible power cable. Furthermore, compared to separate installations, embedding the support mesh within the outer protective layer reduces space requirements and simplifies assembly. The support mesh and outer protective layer complement each other, achieving a better reinforcement effect. Moreover, the porous mesh structure allows the outer protective layer to connect to the inner and outer sides of the support mesh without affecting the overall structural strength of the outer protective layer. This flexible power cable also boasts a simple structure, facilitating manufacturing and reducing production costs. Attached Figure Description

[0015] Figure 1 This is a schematic cross-sectional view of the flexible power cable in an embodiment of this utility model.

[0016] Figure 2 This is an exploded view of the structure of the support mesh and outer protective layer in an embodiment of this utility model.

[0017] Figure 3 This is a schematic cross-sectional view of the flexible power cable in another embodiment of the present invention.

[0018] Figure 4 This is a schematic cross-sectional view of the flexible power cable in another embodiment of the present invention. Detailed Implementation

[0019] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate this utility model, but are not intended to limit its scope.

[0020] The terms “first,” “second,” “third,” “fourth,” etc. (if present) in the specification and claims of this utility model are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.

[0021] The directional terms such as "up," "down," "left," "right," "front," "back," "top," and "bottom" (if present) used in the specification and claims of this utility model are defined according to the position of the structures in the drawings and the relative positions of the structures, and are only for the purpose of clarity and convenience in expressing the technical solution. It should be understood that the use of directional terms should not limit the scope of protection claimed by this utility model.

[0022] like Figure 1 and Figure 2 As shown, the flexible power cable provided in this embodiment of the present invention includes a hollow outer protective layer 1 and multiple conductors 4 (generally at least three) disposed within the outer protective layer 1. The cross-section of the outer protective layer 1 is annular, that is, the outer protective layer 1 has a cylindrical structure. The flexible power cable also includes a support mesh 5, which is a tubular structure (i.e., a cylindrical structure), specifically a cylindrical structure (i.e., a circular structure). The support mesh 5 has multiple mesh holes 51, which are evenly distributed along the axial and circumferential directions of the support mesh 5. The support mesh 5 is embedded within the outer protective layer 1 (i.e., the support mesh 5 is embedded within the tube wall of the cylindrical structure of the outer protective layer 1), and the support mesh 5 is coaxially arranged with the outer protective layer 1, extending along the length direction of the outer protective layer 1.

[0023] Meanwhile, the two parts of the outer protective layer 1 on the inner and outer sides of the support net 5 are connected through the mesh openings 51 on the support net 5. Specifically, in this embodiment, the outer protective layer 1 includes a first part 11 and a second part 12. The first part 11 is located on the inner side of the support net 5, and the second part 12 is located on the outer side of the support net 5. The first part 11 and the second part 12 are connected through the mesh openings 51 on the support net 5. That is, in addition to being located on the inner and outer sides of the support net 5, the outer protective layer 1 is also filled in the mesh openings 51 of the support net 5 (the first part 11 and the second part 12 are connected through the outer protective layer 1 in the mesh openings), thereby making the entire outer protective layer 1 a single structure.

[0024] The flexible power cable provided in this embodiment of the utility model has a support mesh 5 embedded in the outer protective layer 1. The support mesh 5 is equivalent to the skeleton of the outer protective layer 1. Since the support mesh 5 has good structural strength and flexibility, embedding the support mesh 5 in the outer protective layer 1 can improve the structural strength and flexibility of the outer protective layer 1, making the outer protective layer 1 less prone to breakage during bending, thereby improving the bending resistance of the flexible power cable. At the same time, since the support mesh 5 is embedded in the outer protective layer 1, compared with the method of setting the support mesh 5 and the outer protective layer 1 separately (i.e., the support mesh 5 is not embedded in the outer protective layer 1, for example, the support mesh 5 is sleeved in the outer protective layer 1), it can not only reduce the space occupied, but also make the assembly more convenient (no need to assemble the outer protective layer 1 and the support mesh 5 separately). At the same time, the support mesh 5 and the outer protective layer 1 complement each other to achieve a better reinforcement effect (i.e., the support mesh 5 can reinforce the outer protective layer 1, and the outer protective layer 1 can fix the support mesh 5 to prevent the support mesh 5 from slipping, so that the support mesh 5 can better play its role). Furthermore, because the support mesh 5 has a porous mesh structure with multiple mesh openings 51, the two parts of the outer protective layer 1 on the inner and outer sides of the support mesh 5 can be connected through the mesh openings 51, thus not affecting the overall structural strength of the outer protective layer 1 (if the support mesh 5 were a dense structure without mesh openings, it would divide the outer protective layer 1 into inner and outer parts, which would reduce the overall strength of the outer protective layer 1). At the same time, this flexible power cable has a simple structure, is easy to manufacture, and can reduce production costs.

[0025] In one implementation, the outer protective layer 1 is made of rubber. During manufacturing, the outer protective layer 1 can be fabricated on top of the support mesh 5, allowing the support mesh 5 to be embedded within it. For example, during manufacturing, the support mesh 5 is first placed in a mold, then molten rubber raw material is poured into the mold, followed by molding and vulcanization to obtain the outer protective layer 1. It is important to note that the melting temperature of the support mesh 5 must be higher than the vulcanization temperature of the rubber to prevent the support mesh 5 from melting at high temperatures during vulcanization, which could alter its structure.

[0026] As one implementation method, the support net 5 is made of non-metallic material. Specifically, the material of the support net 5 can be polypropylene, nylon, or aramid, that is, the support net 5 can be a mesh structure woven from polypropylene fiber filaments, nylon fiber filaments, or aramid fiber filaments.

[0027] Specifically, because the support net 5 uses the aforementioned non-metallic materials, it not only has good structural strength and flexibility, but is also lightweight and low-cost, which is beneficial for the lightweight design of flexible power cables. At the same time, the melting temperature of the aforementioned non-metallic materials is higher than the vulcanization temperature of rubber (the vulcanization temperature of rubber is generally around 150-160℃, while the melting temperature of the aforementioned non-metallic materials is above 189℃), so it will not deform due to the high-temperature vulcanization process during manufacturing. Meanwhile, since the support net 5 is made of non-metallic material, in order to improve the structural strength of the support net 5, the mesh count 51 of the support net 5 can be set to be relatively large (that is, the aperture of the mesh 51 is smaller and the mesh 51 is denser). For example, the mesh count 51 of the support net 5 can be 50-200 mesh or 100-150 mesh. At the same time, since non-metallic materials are lightweight, even if the mesh count 51 of the support net 5 is large, the impact on the weight of the flexible power cable is small (the larger the mesh count 51 of the support net 5, the heavier it is).

[0028] As another implementation, the support mesh 5 is made of metal. Specifically, the material of the support mesh 5 can be stainless steel or nickel-plated copper, that is, the support mesh 5 can be a mesh structure woven from stainless steel wire or nickel-plated copper wire.

[0029] Specifically, nickel-plated copper wire refers to copper wire with a layer of nickel plated on its surface, thereby improving its corrosion resistance and oxidation resistance. Both stainless steel wire and nickel-plated copper wire possess excellent corrosion resistance and oxidation resistance. When the support mesh 5 is made of metal, the structural strength of the support mesh 5 is higher than that of non-metallic materials, thus giving the outer protective layer 1 higher structural strength. Furthermore, the aforementioned types of metal wire have good flexibility, so they do not affect the bending performance of the flexible power cable. Simultaneously, because both stainless steel wire and nickel-plated copper wire have excellent corrosion resistance and oxidation resistance, oxidation and corrosion will not occur during the fabrication of the outer protective layer 1. However, since metal materials have a higher density than non-metal materials, if the mesh number 51 of the support net 5 is large when the support net 5 is made of metal, the weight of the flexible power cable will be significantly increased. Therefore, the mesh number 51 of the support net 5 can be set to be relatively small (i.e., the aperture of the mesh 51 is larger and the mesh 51 is sparser). For example, the mesh number 51 of the support net 5 can be 5-50 mesh or 5-20 mesh.

[0030] In one implementation, the thickness of the support mesh 5 is 1mm to 5mm, or 1mm to 3mm.

[0031] like Figure 1 and Figure 2As shown, in one embodiment, the support net 5 is a single-layer structure (i.e., the number of support nets 5 is one). The distance L1 between the support net 5 and the outer surface of the outer protective layer 1 (i.e., the distance between the outer surface of the support net 5 and the outer surface of the outer protective layer 1) is greater than the distance L2 between the support net 5 and the inner surface of the outer protective layer 1 (i.e., the distance between the inner surface of the support net 5 and the inner surface of the outer protective layer 1). That is, the support net 5 is closer to the inner surface of the outer protective layer 1, and the wall thickness of the second part 12 of the outer protective layer 1 is greater than the wall thickness of its first part 11. This configuration has two advantages. First, because the distance L1 between the support mesh 5 and the outer surface of the outer protective layer 1 is larger, that is, the wall thickness of the second part 12 of the outer protective layer 1 is thicker, when the outer protective layer 1 is worn, this structure can reduce or avoid the support mesh 5 being exposed and damaged (if the support mesh 5 is close to the surface of the outer protective layer 1, the support mesh 5 is easily exposed after the outer protective layer 1 is worn). Second, it is beneficial to reduce the thickness of the support mesh 5 (i.e., the diameter of the support mesh 5), thereby reducing the weight of the support mesh 5.

[0032] In one implementation, the difference between the spacing L1 and the spacing L2 is 1 / 10 to 1 / 5 of the wall thickness of the outer protective layer 1.

[0033] like Figure 3 As shown, in another embodiment, the support mesh 5 has a multi-layer structure. There are at least two support meshes 5 (two are shown in the figure, but more are possible), the diameters of the at least two support meshes 5 are different, the at least two support meshes 5 are coaxially arranged, and the at least two support meshes 5 are spaced apart within the outer protective layer 1, i.e., the at least two support meshes 5 are spaced and nested together. This arrangement, with multiple support meshes 5 embedded within the outer protective layer 1, further enhances the structural strength of the outer protective layer 1. In one embodiment, the mesh count of the mesh 51 on the outer support mesh 5 (i.e., the support mesh 5 further from the center of the outer protective layer 1) is greater than that on the inner support mesh 5 (i.e., the support mesh 5 closer to the center of the outer protective layer 1). Because the tensile force on the outer support net 5 is greater than that on the inner support net 5 when the flexible power cable is bent, the mesh size 51 of the outer support net 5 is set to be relatively large to improve its structural strength and prevent it from breaking; while the mesh size 51 of the inner support net 5 is set to be relatively small to reduce its weight.

[0034] like Figure 1As shown, in one embodiment, the flexible power cable also includes an insulation layer 3. The cross-section of the insulation layer 3 is annular. The insulation layer 3 wraps around the outside of multiple conductors 4 and is located between the conductors 4 and the outer protective layer 1. The insulation layer 3 can wrap and fix the multiple conductors 4, preventing the position of the conductors 4 from shifting. At the same time, the insulation layer 3 can also improve the structural strength of the flexible power cable, and even when the outer protective layer 1 is worn through, the insulation layer 3 can still provide insulation protection for the conductors 4.

[0035] like Figure 1 As shown, in one embodiment, a fiber braided layer 2 is provided between the insulation layer 3 and the outer protective layer 1. The fiber braided layer 2 can be woven from polyester fibers, nylon fibers, etc., and can further improve the structural strength, flexibility, and bending resistance of the flexible power cable. The fiber braided layer 2 and the support mesh 5 can be made of the same or different materials. Generally, the thickness of the fiber braided layer 2 is greater than the thickness of the support mesh 5.

[0036] like Figure 1 As shown, in one embodiment, multiple wires 4 are arranged close together within the insulation layer 3. Each wire 4 includes an insulating sheath 41 and conductors 42 disposed within the insulating sheath 41. The number of conductors 42 can be one or more, and the conductors 42 can be copper wire, aluminum wire, etc. The insulating sheath 41 has a circular cross-section.

[0037] like Figure 4 As shown, in another embodiment, a flexible central tube 6 is provided at the center of the outer protective layer 1. Multiple conductors 4 are evenly arranged around the circumference of the flexible central tube 6, and adjacent conductors 4 are arranged close to each other. By providing the flexible central tube 6, on the one hand, the flexible central tube 6 can further improve the structural strength of the flexible power cable; on the other hand, since multiple conductors 4 are arranged around the flexible central tube 6, when the flexible power cable is bent, twisted, or torn, after the conductors 4 deform (the conductors 4 will deform when bent), the flexible central tube 6 can absorb the compressive force generated by the conductors 4 during deformation, thus preventing the conductors 4 from breaking.

[0038] like Figure 4 As shown, in one embodiment, a steel wire 61 (the flexible central tube 6 is a solid structure) is embedded in the center of the flexible central tube 6, and the steel wire 61 extends along the length of the flexible central tube 6. By setting the steel wire 61 inside the flexible central tube 6, the toughness of the flexible central tube 6 can be improved, thereby further enhancing the structural strength and bending resistance of the flexible power cable.

[0039] In one implementation, the insulating layer 3 and the insulating outer sheath 41 can be made of insulating materials such as polyurethane, polyester, polyesterimide, and polyamideimide. The flexible central tube 6 can be made of foam, thermoplastic elastomer, or other materials.

[0040] The flexible power cable provided in this embodiment of the invention features a support mesh 5 embedded within the outer protective layer 1. The support mesh 5 acts as the skeleton of the outer protective layer 1. Due to its excellent structural strength and flexibility, embedding the support mesh 5 within the outer protective layer 1 enhances these properties, making it less prone to breakage during bending and thus improving the bending resistance of the flexible power cable. Furthermore, embedding the support mesh 5 within the outer protective layer 1, compared to separate installations, reduces space requirements and simplifies assembly. The complementary relationship between the support mesh 5 and the outer protective layer 1 provides superior reinforcement. Moreover, the porous mesh structure of the support mesh 5, with multiple mesh openings 51, allows the two parts of the outer protective layer 1 on either side of the support mesh 5 to connect through these openings, without affecting the overall structural strength of the outer protective layer 1. This flexible power cable also boasts a simple structure, facilitating manufacturing and reducing production costs.

[0041] The above are merely specific embodiments of this utility model, but the protection scope of this utility model is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this utility model should be included within the protection scope of this utility model. Therefore, the protection scope of this utility model should be determined by the scope of the claims.

Claims

1. A flexible power cable, comprising a hollow outer protective layer (1) and a plurality of conductors (4) disposed within the outer protective layer (1), characterized in that, The flexible power cable also includes a support mesh (5), which is a tubular structure and has multiple mesh holes (51). The support mesh (5) is embedded in the outer protective layer (1) and is coaxially arranged with the outer protective layer (1).

2. The flexible power cable as described in claim 1, characterized in that, The support mesh (5) is made of non-metallic material, and the mesh number of the mesh opening (51) of the support mesh (5) is 50-200 mesh.

3. The flexible power cable as described in claim 1, characterized in that, The support mesh (5) is made of polypropylene, nylon or aramid.

4. The flexible power cable as described in claim 1, characterized in that, The support mesh (5) is made of metal, and the mesh number of the mesh openings (51) of the support mesh (5) is 5-50 mesh.

5. The flexible power cable as described in claim 1, characterized in that, The support mesh (5) is made of stainless steel or nickel-plated copper.

6. The flexible power cable as described in claim 1, characterized in that, The support mesh (5) is a single-layer structure, and the distance between the support mesh (5) and the outer surface of the outer protective layer (1) is greater than the distance between the support mesh (5) and the inner surface of the outer protective layer (1).

7. The flexible power cable as described in claim 1, characterized in that, The support mesh (5) has a multi-layer structure; there are at least two support meshes (5), the diameters of the at least two support meshes (5) are different, the at least two support meshes (5) are coaxially arranged, and the at least two support meshes (5) are spaced apart inside the outer protective layer (1).

8. The flexible power cable as described in claim 7, characterized in that, The mesh count of the mesh openings (51) of the support mesh (5) located on the outer side is greater than the mesh count of the mesh openings (51) of the support mesh (5) located on the inner side.

9. The flexible power cable as described in claim 1, characterized in that, The flexible power cable also includes an insulation layer (3), which is wrapped around the outside of the plurality of conductors (4) and is located between the conductors (4) and the outer protective layer (1).

10. The flexible power cable as described in any one of claims 1-9, characterized in that, A flexible central tube (6) is provided at the center of the outer protective layer (1), and multiple wires (4) are evenly arranged around the circumferential direction of the flexible central tube (6).

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