High-voltage photovoltaic weather-resistant enhanced cable

Abstract

The utility model discloses a high-voltage photovoltaic weather-resistant enhanced cable, which comprises a conductor, a double-layer insulating layer and a protective layer, the surface of the conductor is provided with a corrosion-resistant layer, the double-layer insulating layer is composed of an inner insulating layer and an outer insulating layer, a heat-insulating buffer layer is arranged between the double-layer insulating layer and the protective layer, and the outer insulating layer is provided with a heat-insulating layer. A braid layer is arranged between the heat insulation buffer layer and the protective layer, and a waterproof breathable film is arranged on the surface of the protective layer. According to the utility model, through the well-designed multi-layer composite structure, the cable can resist the comprehensive influence of various severe environment factors such as ultraviolet rays, high and low temperatures, moisture, chemical substances, mechanical stress and the like in an omnibearing and multi-layer manner, and the weather resistance is qualitatively improved. And by virtue of a comprehensive protection structure, the damage of external factors to key structures such as the internal conductor and the insulating layer is effectively reduced, and the service life of the cable is remarkably prolonged. Therefore, the maintenance cost of the photovoltaic power generation system is reduced, and the overall reliability and operation efficiency of the system are improved.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, and in particular to weather-resistant enhanced cables for high-voltage photovoltaic applications. Background Technology

[0002] In the booming photovoltaic power generation industry, high-voltage photovoltaic cables, as a key link in power transmission, must face the challenges of complex, ever-changing, and harsh outdoor environments for a long time.

[0003] Existing cables have significant deficiencies in weather resistance, constantly subjected to intense ultraviolet radiation, severe high and low temperature cycling, corrosion from high humidity environments, and potential damage from various chemicals. This series of adverse factors causes the cable sheath to age rapidly and insulation performance to decline sharply. This not only significantly shortens the cable's lifespan but also increases the operating costs of photovoltaic power generation systems due to frequent replacement and maintenance operations, and creates substantial safety hazards. Therefore, there is an urgent need to design an innovative, weather-resistant enhanced cable for high-voltage photovoltaic systems to lay a solid foundation for the stable and efficient operation of photovoltaic power generation systems. Utility Model Content

[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing a weather-resistant enhanced cable for high-voltage photovoltaic applications.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A weather-resistant reinforced cable for high-voltage photovoltaic applications includes a conductor, a double insulation layer, and a protective layer. The conductor has a corrosion-resistant layer on its surface. The double insulation layer consists of an inner insulation layer and an outer insulation layer. A heat-insulating buffer layer is provided between the double insulation layer and the protective layer. A braided layer is provided between the heat-insulating buffer layer and the protective layer. A waterproof and breathable membrane is provided on the surface of the protective layer.

[0007] Preferably, the corrosion-resistant layer is an alloy layer, and the material of the corrosion-resistant layer is a zinc-aluminum alloy.

[0008] Preferably, the inner insulation layer is made of irradiated cross-linked polyethylene, and the outer insulation layer is made of modified polyvinyl chloride with added ultraviolet absorbers and antioxidants.

[0009] Preferably, the heat insulation buffer layer is made of aerogel felt and silicone rubber sponge, and the heat insulation buffer layer is specifically composed of alternating layers of aerogel felt and silicone rubber sponge.

[0010] Preferably, a layer of wire mesh is wound around the surface of the corrosion-resistant layer, and the wire mesh is made of stainless steel.

[0011] Preferably, the woven layer is made of aramid fiber, and the waterproof and breathable membrane is made of polytetrafluoroethylene.

[0012] The beneficial effects of this utility model are:

[0013] 1. Through a carefully designed multi-layer composite structure, the cable can resist the combined effects of various harsh environmental factors such as ultraviolet rays, high and low temperatures, humidity, chemicals, and mechanical stress in an all-round and multi-layer manner, and its weather resistance has achieved a qualitative leap.

[0014] 2. The selection of materials and structural design for each structural layer fully considers the stability of electrical performance. From the low resistance design of the conductor to the high-efficiency insulation protection of the insulation layer, and the synergistic effect of the shielding layer and waterproof and breathable structure, it ensures that the cable maintains stable electrical insulation performance under different environmental conditions, greatly reducing the risk of electrical faults caused by environmental factors.

[0015] 3. With its comprehensive protective structure, the cable effectively reduces damage to critical structures such as internal conductors and insulation layers caused by external factors, significantly extending the cable's lifespan. This not only lowers the maintenance costs of the photovoltaic power generation system but also improves the overall reliability and operational efficiency of the system. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the high-voltage photovoltaic weather-resistant enhanced cable proposed in this utility model;

[0017] Figure 2 for Figure 1 A schematic diagram of the vertical section structure;

[0018] Figure 3 for Figure 2 An enlarged schematic diagram of the structure at point A.

[0019] In the diagram: 1 conductor, 2 corrosion-resistant layer, 3 wire mesh, 4 inner insulation layer, 5 outer insulation layer, 6 heat insulation buffer layer, 7 braided layer, 8 waterproof and breathable membrane, 9 protective layer. Detailed Implementation

[0020] 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.

[0021] Reference Figure 1-3 This cable features a sophisticated and efficient multi-layered composite structure, consisting of a conductor 1, double insulation layers, and a protective layer 9. Each layer performs its specific function while working in concert to create the cable's superior weather resistance and electrical performance.

[0022] Conductor 1 is made of high-purity copper, which has extremely low resistance, ensuring efficient current transmission with minimal loss. A corrosion-resistant layer 2 is uniformly coated onto the surface of conductor 1 using an advanced electroplating process. This corrosion-resistant layer 2 is made of zinc-aluminum alloy, and thanks to its excellent corrosion resistance, it forms a dense protective film on the surface of conductor 1 in humid, acidic, or alkaline environments, effectively preventing chemical reactions between conductor 1 and external corrosive substances, thus maintaining the conductor 1's good conductivity for a long time.

[0023] In addition, a layer of stainless steel wire mesh 3 is tightly wound around the surface of the corrosion-resistant layer 2. The stainless steel wire mesh 3 not only significantly enhances the mechanical strength of the conductor 1, making it less prone to deformation or breakage when subjected to external pulling or squeezing forces, but also effectively blocks the influence of external electromagnetic interference on the internal current transmission of the conductor 1 due to its excellent electromagnetic shielding performance, ensuring the purity and stability of the current signal.

[0024] The double insulation layer consists of an inner insulation layer 4 and an outer insulation layer 5.

[0025] The inner insulation layer 4 is made of irradiated cross-linked polyethylene. After undergoing a special irradiation cross-linking process, the molecular structure of this material changes from linear to a three-dimensional network structure, thereby greatly improving its electrical insulation performance and mechanical strength. It can reliably isolate conductor 1 from the outside environment under high voltage conditions, preventing current leakage.

[0026] The outer insulation layer 5 is made of modified polyvinyl chloride with added ultraviolet absorbers and antioxidants. The ultraviolet absorbers efficiently capture and convert ultraviolet energy from sunlight, preventing damage to the molecular structure of the insulation layer and effectively preventing aging and embrittlement due to long-term ultraviolet exposure. The antioxidants react with oxygen in the air, consuming it and thus slowing down the oxidation process of the insulation layer, extending its service life.

[0027] The double-layer insulation design not only ensures good insulation performance, but also enhances the ability to resist environmental factors from different angles.

[0028] Between the double insulation layer and the protective layer 9, a heat-insulating buffer layer 6 is provided. This heat-insulating buffer layer 6 is composed of alternating layers of aerogel felt and silicone rubber sponge. Aerogel felt is known for its extremely low thermal conductivity and is an excellent heat insulation material, effectively blocking heat from the external high-temperature environment from being conducted into the cable, preventing the degradation of the internal structural performance of the cable due to excessive temperature. Silicone rubber sponge has excellent elasticity and cushioning performance. When faced with thermal expansion and contraction caused by temperature changes, as well as external mechanical vibration and impact, it can effectively buffer stress through its own elastic deformation, protecting the double insulation layer and the protective layer 9 from mechanical damage.

[0029] Between the heat insulation buffer layer 6 and the protective layer 9, a braided layer 7 made of aramid fiber is added. Aramid fiber is a high-performance fiber material with a tensile strength 5-6 times that of steel wire and a modulus 2-3 times that of steel wire or glass fiber. This gives the braided layer 7 excellent tensile strength, effectively dispersing stress when the cable is subjected to tensile forces, preventing the cable from breaking during stretching. At the same time, the aramid fiber braided layer 7 also has a certain compressive strength, resisting external compression and further protecting the internal structure of the cable.

[0030] A waterproof and breathable membrane 8 is tightly adhered to the outer surface of the protective layer 9. This membrane 8 is made of polytetrafluoroethylene (PTFE), and its microstructure features unique micropores with a pore size between that of water vapor molecules and liquid water molecules. This characteristic allows water vapor molecules to pass freely through the membrane 8, ensuring that moisture inside the cable can be expelled in a timely manner, preventing problems such as decreased insulation performance and corrosion caused by moisture accumulation. Simultaneously, liquid water cannot penetrate the membrane 8, providing a reliable waterproof barrier for the cable in rainy or high-humidity environments. Furthermore, the membrane 8 can also balance the air pressure inside and outside the cable to a certain extent, improving the cable's stability under different environmental conditions.

[0031] Protective layer 9 is made of neoprene rubber, a material renowned for its excellent weather resistance, ozone resistance, chemical corrosion resistance, and flame retardancy. In outdoor environments, neoprene rubber protective layer 9 effectively resists ultraviolet radiation, ozone oxidation, and corrosion from various chemicals. Furthermore, in emergencies such as fires, its flame-retardant properties effectively prevent the spread of flames, providing crucial protection for the safe operation of the photovoltaic power generation system.

[0032] The working principle of this high-voltage photovoltaic weather-resistant reinforced cable can be summarized as follows: A high-purity copper conductor 1 ensures low-loss current transmission; an outer zinc-aluminum alloy corrosion-resistant layer 2 prevents corrosion of the conductor 1; and a stainless steel wire mesh 3 enhances mechanical strength and shields against electromagnetic interference. In the double insulation layer, the inner insulation layer 4 is treated with irradiated cross-linked polyethylene to improve electrical insulation and mechanical properties, and isolates current; the outer insulation layer 5 uses UV absorbers and antioxidants to prevent UV aging and oxidation. The heat-insulating buffer layer 6 uses aerogel felt to block heat, and silicone rubber sponge to buffer stress, protecting the insulation layer and protective layer 9. The aramid fiber braided layer 7, with its high tensile strength and compressive strength, enhances the cable's tensile and compressive strength. The waterproof and breathable membrane 8 allows water vapor to escape, blocks liquid water, and balances air pressure. The outermost neoprene rubber protective layer 9 resists UV rays, ozone, and chemicals, and is flame-retardant. These layers work together to ensure stable current transmission, maintain weather resistance and electrical performance in harsh outdoor environments, and extend the cable's service life.

[0033] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. Weather-resistant enhanced cable for high-voltage photovoltaics, comprising a conductor (1), a double insulating layer and a protective layer (9), characterized in that, The surface of the conductor (1) is provided with a corrosion-resistant layer (2), the double-layer insulation layer is composed of an inner insulation layer (4) and an outer insulation layer (5), a heat insulation buffer layer (6) is arranged between the double-layer insulation layer and the protective layer (9), a braided layer (7) is arranged between the heat insulation buffer layer (6) and the protective layer (9), and the surface of the protective layer (9) is provided with a waterproof and breathable film (8).

2. The weatherability enhanced cable for high voltage photovoltaic according to claim 1, characterized by, The corrosion-resistant layer (2) is an alloy layer, and the material of the corrosion-resistant layer (2) is zinc-aluminum alloy.

3. The weatherability-enhanced cable for high-voltage photovoltaics of claim 2, wherein, The material of the inner insulation layer (4) is irradiation cross-linked polyethylene, and the material of the outer insulation layer (5) is modified polyvinyl chloride added with ultraviolet absorber and antioxidant.

4. The weatherability-enhanced cable for high-voltage photovoltaics of claim 3, wherein, The material of the heat insulation buffer layer (6) is aerogel felt and silicone rubber sponge, and the heat insulation buffer layer (6) is specifically composed of aerogel felt and silicone rubber sponge which are alternately stacked.

5. The weatherability-enhanced cable for high-voltage photovoltaics of claim 4, wherein, The surface of the corrosion-resistant layer (2) is wound with a layer of silk screen (3), and the material of the silk screen (3) is stainless steel.

6. The weatherability-enhanced cable for high-voltage photovoltaics of claim 5, wherein, The material of the braided layer (7) is aramid fiber, and the material of the waterproof and breathable film (8) is polytetrafluoroethylene.

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