Bending-resistant flexible power cable

Abstract

The utility model provides a bending-resistant flexible power cable, comprising a hollow outer protection layer and a plurality of leads arranged in the outer protection layer, the bending-resistant flexible power cable also comprises a spiral spring tube, the spring tube is embedded in the outer protection layer, and the spring tube 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 that is resistant to bending. 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 is resistant to bending, which 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 that is resistant to bending, including a hollow outer protective layer and multiple conductors disposed within the outer protective layer. The flexible power cable also includes a spiral spring tube embedded in the outer protective layer and coaxially disposed with the outer protective layer.

[0005] In one possible implementation, the spring tube comprises a plurality of spiral coils connected sequentially along its axial direction, the distance between adjacent spiral coils being a, the outer diameter of the outer protective layer being b, a = k * b, and the value of k being 0.3 to 0.6.

[0006] In one feasible manner, the distance between adjacent spiral coils is 4 mm to 10 mm.

[0007] In one possible implementation, the spring tube is formed by bending a metal wire with a diameter of 1 mm to 5 mm.

[0008] In one possible implementation, the distance between the spring tube and the outer surface of the outer protective layer is greater than the distance between the spring tube and the inner surface of the outer protective layer.

[0009] In one possible implementation, the number of spring tubes is two, the two spring tubes are coaxially arranged, and the two spring tubes are arranged to form a double helix structure.

[0010] In one possible implementation, the spring tube is made of stainless steel or nickel-plated copper, and the outer protective layer is made of rubber.

[0011] In one possible implementation, the bend-resistant 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.

[0012] In one possible implementation, a fiber braided layer is provided between the insulating layer 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, by embedding a helical spring tube within the outer protective layer, improves the flexibility and deformation recovery performance of the outer protective layer, thereby enhancing the bending resistance of the flexible power cable. Furthermore, the spring tube acts as a skeleton within the outer protective layer, significantly increasing its structural strength and thus the overall structural strength of the flexible power cable. Moreover, compared to separate installations, embedding the spring tube within the outer protective layer reduces space requirements and simplifies assembly. The synergistic effect of the spring tube and outer protective layer provides enhanced reinforcement. Additionally, this flexible power cable has a simple structure, is easy to manufacture, and reduces production costs. Attached Figure Description

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

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

[0017] Figure 3 This is a schematic diagram of the spring tube in another embodiment of the present invention.

[0018] Figure 4 This is a cross-sectional schematic diagram of a bend-resistant flexible power cable according to 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 with bend resistance 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 tubular structure. The flexible power cable with bend resistance also includes a spiral spring tube 5, which is embedded within the outer protective layer 1 (i.e., the spring tube 5 is embedded within the tube wall of the cylindrical outer protective layer 1). The spring tube 5 is coaxially arranged with the outer protective layer 1 and extends along the length direction of the outer protective layer 1.

[0023] The flexible power cable with bend resistance provided in this embodiment of the invention improves the flexibility and deformation recovery performance of the outer protective layer 1 by embedding a spiral spring tube 5 inside the outer protective layer 1. On the one hand, the spring tube 5 has good elastic deformation capability (i.e., axial expansion and contraction performance) and resistance to radial deformation. This improves the bend resistance of the flexible power cable. On the other hand, the spring tube 5 acts as a skeleton for the outer protective layer 1, significantly increasing its structural strength and thus improving the structural strength of the flexible power cable. Because the spring tube 5 is embedded within the outer protective layer 1, compared to a separate arrangement (i.e., the spring tube 5 is not embedded within the outer protective layer 1, but rather fitted inside it), it not only reduces space requirements but also simplifies assembly (eliminating the need for separate assembly of the outer protective layer 1 and the spring tube 5). Furthermore, the spring tube 5 and the outer protective layer 1 complement each other to achieve better reinforcement (the spring tube 5 reinforces the outer protective layer 1, while the outer protective layer 1 secures the spring tube 5, preventing slippage and allowing it to function more effectively). Additionally, this flexible power cable has a simple structure, is easy to manufacture, and reduces production costs.

[0024] like Figure 1 and Figure 2 As shown, in one embodiment, the spring tube 5 includes a plurality of spiral coils 51 connected sequentially along its axial direction (i.e., the spring tube 5 is formed by connecting a plurality of spiral coils 51 sequentially along its axial direction). Adjacent spiral coils 51 are spaced apart, with a distance 'a' between them. The outer diameter of the outer protective layer 1 is 'b', where a = k * b, and k is 0.3 to 0.6. That is, the distance 'a' between adjacent spiral coils 51 is proportional to the outer diameter 'b' of the outer protective layer 1. For example, when the outer diameter 'b' of the outer protective layer 1 is 10 mm, the distance 'a' between adjacent spiral coils 51 is 3 mm to 6 mm.

[0025] Specifically, because the spiral coils 51 of the spring tube 5 in this embodiment are spaced apart (i.e., the spring tube 5 is gap-wound), compared to a tightly wound spring tube (i.e., the spiral coils in the spring tube are closely arranged), the gap-wound spring tube 5 has better elastic deformation capability (i.e., axial expansion and contraction performance), thereby effectively improving the flexibility and bending resistance of the outer protective layer 1. At the same time, the spring tube 5 is lighter, which helps to reduce the weight of the flexible power cable. Meanwhile, by limiting the distance 'a' between adjacent spiral coils 51, the spring tube 5 has both good elasticity and structural strength (if the distance 'a' is too small, the elasticity of the spring tube 5 is poor and the weight is heavier; if the distance 'a' is too large, the structural strength of the spring tube 5 is poor, and more parts of the outer protective layer 1 are not supported by the spring tube 5, resulting in a poor effect on improving the structural strength of the outer protective layer 1).

[0026] In one implementation, the distance between adjacent spiral coils 51 is 4mm to 10mm.

[0027] like Figure 2 As shown, in one embodiment, the spring tube 5 is formed by bending a metal wire (not labeled) with a diameter of 1 mm to 5 mm. Alternatively, the diameter of the metal wire may be 1 mm to 3 mm. This gives the spring tube 5 good elasticity and structural strength.

[0028] In one embodiment, the spring tube 5 is made of stainless steel or nickel-plated copper, meaning the aforementioned metal wire is stainless steel wire or nickel-plated copper wire. 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.

[0029] 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 spring tube 5, allowing the spring tube 5 to be embedded within it. For example, during manufacturing, the spring tube 5 is first placed in a mold, then molten rubber material is poured into the mold, followed by molding and vulcanization of the rubber material to obtain the outer protective layer 1. Since the spring tube 5 is made of stainless steel or nickel-plated copper, both stainless steel wire and nickel-plated copper wire have excellent corrosion resistance and oxidation resistance, thus the spring tube 5 will not be corroded or oxidized during manufacturing.

[0030] like Figure 1As shown, in one embodiment, the distance L1 between the spring tube 5 and the outer surface of the outer protective layer 1 (i.e., the distance between the outer surface of the spring tube 5 and the outer surface of the outer protective layer 1) is greater than the distance L2 between the spring tube 5 and the inner surface of the outer protective layer 1 (i.e., the distance between the inner surface of the spring tube 5 and the inner surface of the outer protective layer 1), meaning the spring tube 5 is closer to the inner surface of the outer protective layer 1. This arrangement has several advantages. First, because the distance L1 between the spring tube 5 and the outer surface of the outer protective layer 1 is larger, meaning the wall thickness between the outer surface of the outer protective layer 1 and the spring tube 5 is thicker, this structure can reduce or prevent damage to the spring tube 5 when the outer protective layer 1 is worn (if the spring tube 5 is close to the surface of the outer protective layer 1, it is more likely to be exposed after the outer protective layer 1 wears down). Second, it helps to reduce the thickness of the spring tube 5 (i.e., the diameter of the spiral coil 51), thereby reducing the weight of the spring tube 5.

[0031] 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.

[0032] like Figure 1 and Figure 2 As shown, in one embodiment, the number of spring tubes 5 is one, that is, a spring tube 5 is embedded in the outer protective layer 1.

[0033] like Figure 3 As shown, in another embodiment, there are two spring tubes 5, meaning that two spring tubes 5 are embedded within the outer protective layer 1. These two spring tubes 5 are coaxially arranged, forming a double helix structure (i.e., the spiral coils 51 of one spring tube 5 are located between adjacent spiral coils 51 in the other spring tube 5). This arrangement further improves the structural strength and bending resistance of the outer protective layer 1, while each spring tube 5 retains its original elasticity (i.e., it does not need to be wound too tightly).

[0034] like Figure 1 As shown, in one embodiment, the bend-resistant 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 1As 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 the fiber braided layer 2 can further improve the structural strength, flexibility, and bending resistance of the flexible power cable.

[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 with bend resistance provided in this embodiment of the invention improves the flexibility and deformation recovery performance of the outer protective layer 1 by embedding a spiral spring tube 5 inside the outer protective layer 1. On the one hand, the spring tube 5 has good elastic deformation capability and resistance to radial deformation; embedding it inside the outer protective layer 1 improves the flexibility and deformation recovery performance of the outer protective layer 1, thereby improving the bend resistance of the flexible power cable. On the other hand, the spring tube 5 acts as a skeleton for the outer protective layer 1, significantly improving its structural strength and thus the structural strength of the flexible power cable. Furthermore, embedding the spring tube 5 inside the outer protective layer 1, compared to a separate arrangement, not only reduces space occupation but also facilitates assembly. The spring tube 5 and the outer protective layer 1 complement each other to achieve a better reinforcement effect. Additionally, this flexible power cable has a simple structure, is easy to manufacture, and reduces 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 resistant to bending, comprising a hollow outer protective layer (1) and a plurality of conductors (4) disposed within the outer protective layer (1), characterized in that, The bend-resistant flexible power cable also includes a spiral spring tube (5), which is embedded in the outer protective layer (1) and is coaxially arranged with the outer protective layer (1).

2. The flexible power cable with bend resistance as described in claim 1, characterized in that, The spring tube (5) includes a plurality of spiral coils (51) connected sequentially along its axial direction. The distance between adjacent spiral coils (51) is a, and the outer diameter of the outer protective layer (1) is b, where a = k * b, and the value of k is 0.3 to 0.

6.

3. The flexible power cable with bend resistance as described in claim 2, characterized in that, The distance between adjacent spiral coils (51) is 4 mm to 10 mm.

4. The flexible power cable with bend resistance as described in claim 1, characterized in that, The spring tube (5) is formed by bending a metal wire, the diameter of which is 1mm to 5mm.

5. The flexible power cable with bend resistance as described in claim 1, characterized in that, The distance (L1) between the spring tube (5) and the outer surface of the outer protective layer (1) is greater than the distance (L2) between the spring tube (5) and the inner surface of the outer protective layer (1).

6. The flexible power cable with bend resistance as described in claim 1, characterized in that, The number of spring tubes (5) is two, the two spring tubes (5) are coaxially arranged, and the two spring tubes (5) are arranged to form a double helix structure.

7. The flexible power cable with bend resistance as described in claim 1, characterized in that, The spring tube (5) is made of stainless steel or nickel-plated copper, and the outer protective layer (1) is made of rubber.

8. The flexible power cable resistant to bending as described in claim 1, characterized in that, The bend-resistant flexible power cable also includes an insulation layer (3), which wraps around the outside of the plurality of conductors (4) and is located between the conductors (4) and the outer protective layer (1).

9. The flexible power cable with bend resistance as described in claim 8, characterized in that, A fiber braided layer (2) is provided between the insulating layer (3) and the outer protective layer (1).

10. The flexible power cable with bend resistance 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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