Aluminum alloy core silicone rubber cable

Abstract

The utility model relates to an aluminum alloy core silicone rubber cable, and belongs to the technical field of cables. The cable sequentially comprises a second-class aluminum alloy conductor, a hot melt adhesive bonding layer, a silicone rubber insulating layer, a buffer layer, a wrapping layer, an armor layer and a nylon protective layer from inside to outside, the buffer layer comprises a glass fiber mesh belt with a plain weaving structure and polyester resin coatings on the two sides, the armor layer is of a tinned copper wire and galvanized iron wire spaced winding structure, and the wrapping layer is of a 2-3-layer halogen-free low-smoke flame-retardant glass wool cloth belt or mica tape overlapped wrapping structure. Through the multi-layer collaborative design, the cable improves the damage resistance, wear resistance and weather resistance, adapts to wind power severe scenes, prolongs the service life, reduces the operation and maintenance cost and the shutdown risk, and meets the requirements of the wind power industry.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of cables, in particular to an aluminum alloy core silicone rubber cable. BACKGROUND

[0002] Under the promotion of the domestic "double carbon" goal, as the main clean energy, onshore wind power continues to optimize the layout, and offshore wind power has entered the stage of large-scale development. The demand for high-voltage and corrosion-resistant silicone rubber insulation lead cables is particularly strong. Such cables are suitable for high-frequency operation scenarios of wind turbine motor spindles and rotors, can cope with harsh environments such as high humidity and salt spray on the sea and large temperature differences on land, and become key components for stable operation of wind turbines.

[0003] However, the silicone rubber cable has poor mechanical properties and the insulation layer is prone to scratching and cracking, which causes the wind turbine motor to malfunction and causes significant economic losses. Therefore, it is particularly urgent to study a silicone rubber cable with good damage resistance. CONTENT OF THE INVENTION

[0004] The application aims to improve the damage resistance of the silicone rubber cable during construction and long-term operation, thereby prolonging the service life of the cable as a whole and reducing operation and maintenance costs.

[0005] To achieve the above-mentioned purpose, the application provides an aluminum alloy core silicone rubber cable, which comprises, from the inside to the outside, a type II aluminum alloy conductor, a hot melt adhesive layer, a silicone rubber insulation layer, a buffer layer, a wrapping layer, an armor layer and a nylon protective layer, wherein: the buffer layer comprises a glass fiber mesh belt with a plain weave structure and first and second polyester resin coatings respectively arranged on the two side surfaces of the glass fiber mesh belt; the armor layer adopts an interval winding structure in which tinned copper wires and galvanized iron wires are arranged alternately, and the wrapping layer adopts a 2-3 layer superimposed wrapping structure of halogen-free low-smoke flame-retardant glass cloth tape or mica tape to tightly cover the outer periphery of the buffer layer.

[0006] As a further improvement of the application, the thickness of the buffer layer is 0.5-1 mm, the thickness of the glass fiber mesh belt is 0.3-0.6 mm, the thickness of the first polyester resin coating is 0.2-0.4 mm, and the thickness of the second polyester resin coating is 0.2-0.4 mm.

[0007] As a further improvement of the application, the warp and weft density of the plain weave structure is 16x16 strands / cm-24x24 strands / cm, the mesh shape is a regular hexagon, and the mesh side length is 0.8-1.5 mm; wherein: the diameter of the warp glass fiber monofilament is 18-25 pm, and the diameter of the weft glass fiber monofilament is 15-20 pm.

[0008] As a further improvement of the application, the buffer layer further comprises a heat-seal structure at the edge, the heat-seal structure surrounds the edge of the buffer layer, and the width of the heat-seal structure is 1-2 mm.

[0009] As a further improvement of the application, the thickness of the hot melt adhesive layer is 0.1-0.3 mm.

[0010] As a further improvement of the application, the thickness of the silicone rubber insulation layer is 0.3-15 mm.

[0011] As a further improvement of the application, the winding pitch of the armor layer is 8-12 times the outer diameter of the armor layer, and the braiding coverage of the tinned copper wire is not less than 85%, and the braiding coverage of the galvanized iron wire is not less than 80%.

[0012] As a further improvement of the application, the diameter of the tinned copper wire is 0.3-0.8 mm, and the diameter of the galvanized iron wire is 0.3-0.8 mm.

[0013] As a further improvement of the application, the thickness of the nylon protective layer is 0.4-0.6 mm.

[0014] As a further improvement of the application, the total thickness of the wrapping layer is 0.3-0.6 mm.

[0015] The beneficial effects of the application are that the aluminum alloy core silicone rubber cable has a multi-layer synergistic structure design: a type II aluminum alloy conductor is used to replace a copper cable, which greatly reduces the cost and ensures the load capacity; and the hot melt adhesive layer outside the conductor can avoid wrinkles and delamination of the insulation layer, ensuring the insulation reliability.

[0016] The composite structure of the buffer layer has impact resistance, air permeability and heat dissipation performance, and cooperates with the flat wrapping layer to improve the protection stability and improve the mechanical performance of the traditional silicone rubber cable.

[0017] The wrapping layer, the armor layer and the nylon protective layer form multiple protections, and the armor layer is arranged by metal wires to realize functional complementation and make up for the short board of the softness of the aluminum alloy core.

[0018] The overall structure significantly improves the damage resistance of the cable during construction, laying and long-term operation, enhances the wear resistance and weather resistance, adapts to the harsh environment of wind power, prolongs the service life of the cable, reduces the operation and maintenance cost and downtime risk of wind power equipment, and provides reliable protection for stable and efficient operation of the wind power industry. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 The figure is a structural schematic diagram of the aluminum alloy core silicone rubber cable of the application.

[0020] In the figure: 1, aluminum alloy conductor of the second category; 2, hot melt adhesive layer; 3, silicone rubber insulation layer; 4, buffer layer; 5, wrapping layer; 6, armored layer; 7, nylon protective layer. DETAILED DESCRIPTION

[0021] The technical solutions of the present application will be further described in detail below in combination with the drawings and examples. The following technical solutions and examples are used to illustrate the present application, but not to limit the scope of the present application.

[0022] The terms "first", "second", "third", "fourth" and the like (if any) in the specification and claims of the present application are used to distinguish similar objects, and do not necessarily describe a particular order or sequence.

[0023] The terms "up", "down", "left", "right", "front", "back", "top", "bottom" and the like (if any) in the specification and claims of the present application are defined in terms of the position of the structures in the drawings and the position of the structures relative to each other, only to express the technical solutions clearly and conveniently. It should be understood that the use of the terms should not limit the scope of the application claimed.

[0024] To solve the technical problem of poor damage resistance of existing silicone rubber cables during construction laying (dragging, bending, extrusion) and long-term operation, referring to the structural schematic diagram of Figure 1 The present application provides an aluminum alloy core silicone rubber cable, which comprises, from inside to outside, a second category aluminum alloy conductor 1, a hot melt adhesive layer 2, a silicone rubber insulation layer 3, a buffer layer 4, a wrapping layer 5, an armored layer 6 and a nylon protective layer 7, wherein: the buffer layer 4 comprises a glass fiber mesh belt with a plain weave structure, and a first polyester resin coating and a second polyester resin coating respectively arranged on the two side surfaces of the glass fiber mesh belt; the armored layer 6 adopts an interval winding structure with tin-plated copper wires and galvanized iron wires arranged alternately, and the wrapping layer 5 adopts a 2-3 layer superimposed wrapping structure of halogen-free low-smoke flame-retardant glass cloth tape or mica tape to tightly cover the outer periphery of the buffer layer 4.

[0025] Based on the above technical solution, the aluminum alloy core silicone rubber cable provided by the present application solves the technical problems of high cost, poor mechanical properties, easy scratching and cracking of the insulation layer, and insufficient softness of the aluminum alloy core cable leading to easy damage during laying and operation of the existing fan silicone rubber cable, through the multi-layer collaborative structure design of the second category aluminum alloy conductor 1, the hot melt adhesive layer 2, the silicone rubber insulation layer 3, the buffer layer 4, the wrapping layer 5, the armored layer 6 and the nylon protective layer 7 from inside to outside, and the targeted optimization of the buffer layer 4. Specifically as follows:

[0026] Firstly, the second-class aluminum alloy conductor 1 is used to replace the traditional copper cable, which greatly reduces the production cost of the cable under the premise of ensuring that the cable carrying capacity meets the rated operation requirements, and meets the urgent needs of reducing the cost of the current fan; at the same time, in view of the problem that the second-class aluminum alloy conductor 1 is hard, has a large bending radius and is easy to cause the insulation layer to wrinkle and separate, a hot melt adhesive layer 2 is arranged outside the conductor, which can fully bond the conductor and the silicone rubber insulation layer 3 at the operating temperature of the cable, effectively avoiding the separation phenomenon and ensuring the reliability of the cable insulation.

[0027] Secondly, the insulation layer is matched with the buffer layer 4 of the outer layer, the structure of the buffer layer 4 endows it with excellent performance, which can effectively resist external mechanical pressure and avoid damage to the insulation layer caused by extrusion, and at the same time, the structure of the buffer layer 4 has good air permeability, which can optimize the heat dissipation effect of the cable, and the flat wrapping layer wrapped outside the buffer layer 4 has high strength, which further improves the stability of the buffer protection and improves the defects of the traditional silicone rubber cable, such as poor mechanical properties, easy to scratch and crack.

[0028] Further, the wrapping layer 5, the armor layer 6 and the nylon protective layer 7 form a multi-layer external protection system, the wrapping layer 5 provides basic protection and flame retardant assistance for the internal structure, the armor layer 6 realizes function complementation through the interval arrangement of two kinds of metal wires, and the nylon protective layer 7 can effectively avoid the cable from being impacted and abraded in the process of installation, transportation and laying. The structures of each layer are closely matched from inside to outside and functionally cooperative, which not only makes up for the short board of the softness of the aluminum alloy core cable, but also significantly improves the anti-damage ability of the cable in the process of construction and laying (dragging, bending, extrusion) and long-term operation through the synergistic effect of the multi-layer protection structure, and at the same time, the wear resistance and weather resistance of the cable are enhanced, so that it can adapt to the high-frequency operation scene of the spindle and rotor of the fan motor, as well as the harsh environment of high humidity and salt spray at sea and large temperature difference on land, finally greatly prolongs the overall service life of the cable, reduces the operation and maintenance cost and downtime risk of the wind power equipment, and provides reliable protection for the stable and efficient operation of the wind power industry.

[0029] In an optional embodiment, the thickness of the buffer layer 4 is 0.5-1 mm, the thickness of the glass fiber mesh belt is 0.3-0.6 mm, the thickness of the first polyester resin coating layer is 0.2-0.4 mm, and the thickness of the second polyester resin coating layer is 0.2-0.4 mm; the warp and weft density of the plain weave structure is 16×16 strands / cm-24×24 strands / cm, the mesh shape is a regular hexagon, and the mesh side length is 0.8-1.5 mm; wherein: the diameter of the warp glass fiber monofilament is 18-25 μm, and the diameter of the weft glass fiber monofilament is 15-20 μm; the buffer layer 4 further comprises a heat sealing structure at the edge, the heat sealing structure surrounds the edge of the buffer layer 4, and the width of the heat sealing structure is 1-2 mm.

[0030] Based on the above technical scheme, the buffer layer 4 is limited to a total thickness of 0.5-1 mm, matched with a glass fiber mesh belt thickness of 0.3-0.6 mm and a first and second polyester resin coating thickness of 0.2-0.4 mm each, forming a composite protection structure with hierarchical thickness adaptation and compact structure, which not only ensures the overall load capacity and protection strength of the buffer layer 4, but also avoids affecting the overall flexibility and laying convenience of the cable due to excessive thickness; the plain weave structure adopts a warp density of 16x16 strands / cm-24x24 strands / cm, a regular hexagonal mesh with a side length of 0.8-1.5 mm, and a design of a warp glass fiber monofilament diameter of 18-25 μm and a weft glass fiber monofilament diameter of 15-20 μm, which optimizes the air permeability of the buffer layer 4 to improve the cable heat dissipation effect while ensuring the stress uniformity and structural stability of the woven structure, which can effectively disperse external mechanical pressure; and the heat sealing structure around the edge of the buffer layer 4 with a width of 1-2 mm further strengthens the overall integrity of the edge of the buffer layer 4, avoids the problem of loose and off-threading of the edge of the woven structure, and prevents damage to the internal insulation layer due to edge defects during cable laying and operation. The synergistic design of the above dimensions and structures makes the buffer layer 4 have good impact resistance, extrusion resistance, air permeability and structural stability, effectively compensating for the lack of softness of the aluminum alloy core cable and the vulnerability of the silicone rubber insulation layer 3, and significantly improving the damage resistance of the cable in the construction dragging, bending, extrusion and long-term high-frequency operation scenarios.

[0031] In an optional embodiment, the thickness of the hot melt adhesive layer 2 is 0.1-0.3 mm, the thickness of the silicone rubber insulation layer 3 is 0.3-15 mm, the thickness of the nylon protective layer 7 is 0.4-0.6 mm, and the total thickness of the wrapping layer 5 is 0.3-0.6 mm; the winding pitch of the armor layer 6 is 8-12 times the outer diameter of the armor layer 6, the braiding coverage of the tinned copper wire is not less than 85%, the braiding coverage of the galvanized iron wire is not less than 80%, the diameter of the tinned copper wire is 0.3-0.8 mm, and the diameter of the galvanized iron wire is 0.3-0.8 mm.

[0032] Based on the above technical scheme, through the accurate matching design of the key size and structure parameters of each layer, the synergistic optimization of the overall performance of the cable is realized, and the technical problems of high cost, poor mechanical performance, easy damage of the insulation layer and insufficient softness of the aluminum alloy core in the prior art are effectively solved: the thickness design of the hot melt adhesive layer 0.1mm-0.3mm can ensure the close fit with the second type of aluminum alloy conductor 1 and the silicone rubber insulation layer 3, effectively avoid the risk of insulation layer folding and delamination caused by large conductor hardness and large bending radius during laying, and will not increase the overall rigidity of the cable; the width of the silicone rubber insulation layer 0.3-15mm can flexibly adapt to the scene demand of wind power of different voltage grades, and ensure the insulation reliability of the cable under the rated operating conditions; the total thickness of the wrapping layer 0.3-0.6mm cooperates with the compact wrapping structure to provide stable support and basic protection for the internal buffer layer 4, and forms a close fit hierarchical relationship with the outer armor layer 6.

[0033] In addition, the armor layer 6 adopts 0.3-0.8mm diameter tin-plated copper wire and galvanized iron wire, cooperates with the weaving coverage rate of not less than 85% and 80%, and the winding pitch design of the outer diameter of the armor layer 6 8-12 times, which can ensure the structural compactness and mechanical protection strength of the armor layer 6, effectively resist external impact and abrasion, and absorb the tensile stress during laying, and also take into account the flexible adaptability of the cable, which makes up for the short board of the softness of the aluminum alloy core cable; the thickness design of the outermost nylon protective layer 0.4-0.6mm forms a reliable final protective barrier, which can avoid damage to the cable during installation, transportation and other links.

[0034] The synergistic design of the size and structure parameters of each layer makes the cable components form a functional complementary and hierarchical adaptive organic whole, significantly improves the anti-damage ability of the cable during construction laying (dragging, bending, extruding) and long-term high-frequency operation, enhances the wear resistance and weather resistance of the cable, adapts to harsh environments such as high humidity and salt spray on the sea and large temperature difference on land, and finally prolongs the overall service life of the cable under the premise of ensuring that the cable current-carrying capacity meets the rated operation requirements, reduces the operation and maintenance cost and downtime risk of wind power equipment, and realizes significant cost advantage by replacing copper cable with aluminum alloy core, which provides reliable protection for the stable and efficient operation of wind power industry.

[0035] In an optional embodiment, the components of the second-class aluminum alloy conductor 1 include, in mass percentage: 0.1% Si, 0.30-0.8% Fe, 0.15-0.30% Cu, 0.05% Mg, 0.05% Zn, 0.001-0.04% B, no more than 0.03% of each of the other elements and no more than 0.10% in total, and the balance being Al. The tensile strength of the conductor monofilament is 98-159 MPa, and the elongation at break is no less than 10%. By specifying the specific components and mechanical property parameters of the second-class aluminum alloy conductor 1, the cost can be greatly reduced while replacing traditional copper cables, the electrical conductivity and structural stability of the conductor are ensured, and the long-term operation requirements of the wind power scene are met.

[0036] In an optional embodiment, the silicone rubber insulation layer 3 is a high-tear-resistance silicone rubber material with a tensile strength ≥ 8 MPa, an elongation at break ≥ 200%, a tear strength ≥ 10 N / mm, and a volume resistivity ≥ 10 16 Ω•m. The performance parameters of the high-tear-resistance silicone rubber insulation layer 3 are designed to specifically improve the poor mechanical properties and easy scratching and cracking of traditional silicone rubber cables, and to improve the durability of the insulation structure.

[0037] In an optional embodiment, the first and second polyester resin coating layers of the buffer layer 4 are obtained by impregnating a glass fiber mesh belt with polyester resin, and together with the glass fiber mesh belt, form a buffer structure with high strength, impact resistance, high modulus, and low elongation, with a total tensile strength of 1500 N / cm. The nylon protective layer 7 is a high-temperature-resistant nylon material used to resist external impact and protect the internal structure. The wrapping layer 5 is formed by tightly wrapping a halogen-free low-smoke flame-retardant glass silk cloth belt or a mica belt, and the application of this material enables the wrapping layer 5 to play a basic protection and flame-retardant auxiliary role.

[0038] In a specific embodiment, as Figure 1As shown, the application provides an aluminum alloy core silicone rubber cable, which is sequentially provided from inside to outside with a second-class aluminum alloy conductor 1, a hot melt adhesive layer 2, a silicone rubber insulation layer 3, a buffer layer 4, a wrapping layer 5, an armored layer 6 and a nylon protective layer 7; wherein the buffer layer 4 comprises a glass fiber mesh belt with a plain weave structure and a first polyester resin coating and a second polyester resin coating respectively provided on the two side surfaces of the glass fiber mesh belt, the overall thickness of the buffer layer 4 is 0.8mm, wherein the thickness of the glass fiber mesh belt is 0.4mm, the thickness of the first polyester resin coating is 0.2mm, and the thickness of the second polyester resin coating is 0.2mm, the warp and weft density of the plain weave structure is 20x20 strands / cm, the mesh shape is a regular hexagon, the mesh side length is 1.2mm, the warp glass fiber monofilament diameter is 22μm, the weft glass fiber monofilament diameter is 18μm, and the buffer layer 4 further comprises a heat-seal structure surrounding the edge thereof, the width of the heat-seal structure is 1.5mm; the thickness of the hot melt adhesive layer 2 is 0.2mm, which tightly covers the outer periphery of the second-class aluminum alloy conductor 1; the thickness of the silicone rubber insulation layer 3 is 5mm, which covers the outer side of the hot melt adhesive layer 2; the wrapping layer 5 adopts a 2-layer superimposed wrapping structure of halogen-free low-smoke flame-retardant glass cloth belt, which tightly covers the outer periphery of the buffer layer 4, and the total thickness of the wrapping layer 5 is 0.4mm; the armored layer 6 adopts an interval winding structure of tinned copper wire and galvanized iron wire arranged alternately, wherein the diameter of the tinned copper wire is 0.5mm, the diameter of the galvanized iron wire is 0.6mm, the winding pitch of the armored layer 6 is 10 times the outer diameter of the armored layer 6, and it is calculated that the weaving coverage rate of the tinned copper wire is 90% and the weaving coverage rate of the galvanized iron wire is 85%; the thickness of the nylon protective layer 7 is 0.5mm, which tightly covers the outer periphery of the armored layer 6 to form a complete cable protection structure.

[0039] The above series of detailed descriptions are only specific descriptions of the feasible embodiments of the application, which are not used to limit the protection scope of the application, and equivalent embodiments or changes made without departing from the spirit of the application should be included in the protection scope of the application.

Claims

1. An aluminum alloy core silicone rubber cable characterized by, From inside to outside, it comprises a second type of aluminum alloy conductor, a hot melt adhesive layer, a silicone rubber insulation layer, a buffer layer, a wrapping layer, an armored layer and a nylon protective layer, wherein: the buffer layer comprises a glass fiber mesh belt with a plain weave structure and a first polyester resin coating and a second polyester resin coating respectively arranged on the two side surfaces of the glass fiber mesh belt; the armored layer adopts an interval winding structure of alternating arrangement of tinned copper wire and galvanized iron wire, and the wrapping layer adopts a 2-3 layer superimposed wrapping structure of halogen-free low smoke retardant glass silk cloth belt or mica tape to tightly wrap the outer periphery of the buffer layer.

2. The aluminum alloy core silicone rubber cable of claim 1, wherein, The thickness of the buffer layer is 0.5-1mm, the thickness of the glass fiber mesh belt is 0.3-0.6mm, the thickness of the first polyester resin coating is 0.2-0.4mm, and the thickness of the second polyester resin coating is 0.2-0.4mm.

3. The aluminum alloy core silicone rubber cable of claim 1, wherein, The warp and weft density of the plain weave structure is 16×16 root / cm-24×24 root / cm, the mesh shape is regular hexagon, and the mesh side length is 0.8-1.5mm; wherein: the diameter of the warp glass fiber monofilament is 18-25μm, and the diameter of the weft glass fiber monofilament is 15-20μm.

4. The aluminum alloy core silicone rubber cable of claim 1, wherein, The buffer layer further comprises a heat sealing structure at the edge, the heat sealing structure surrounds the edge of the buffer layer, and the width of the heat sealing structure is 1-2mm.

5. The aluminum alloy core silicone rubber cable of claim 1, wherein, The thickness of the hot melt adhesive layer is 0.1-0.3mm.

6. The aluminum alloy core silicone rubber cable of claim 1, wherein, The thickness of the silicone rubber insulation layer is 0.3-15mm.

7. The aluminum alloy core silicone rubber cable of claim 1, wherein, The winding pitch of the armored layer is 8-12 times of the outer diameter of the armored layer, the weaving coverage rate of the tinned copper wire is not less than 85%, and the weaving coverage rate of the galvanized iron wire is not less than 80%.

8. The aluminum alloy core silicone rubber cable of claim 7, wherein, The diameter of the tinned copper wire is 0.3-0.8mm, and the diameter of the galvanized iron wire is 0.3-0.8mm.

9. The aluminum alloy core silicone rubber cable of claim 1, wherein, The thickness of the nylon protective layer is 0.4-0.6mm.

10. The aluminum alloy core silicone rubber cable of claim 1, wherein, The total thickness of the wrapping layer is 0.3-0.6mm.

Images