Novel environment-friendly aluminum alloy core waterproof power cable for railway system
By improving the aluminum alloy conductor structure and multi-layer water-blocking design, the problem of high water permeability in traditional railway cables has been solved, resulting in cost reduction and improved insulation performance, ensuring the stable operation of the cables in the railway system.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-14
- Publication Date
- 2026-03-31
AI Technical Summary
Traditional railway power cables use copper conductors and polyvinyl chloride materials, which have high water permeability, leading to a decrease in insulation resistance, easy breakdown, and impact on transportation, and are also costly.
It adopts an irregularly shaped aluminum alloy conductor, cross-linked polyethylene insulation layer, multi-layer water-blocking structure and galvanized steel wire armor. The polyethylene molecular structure and multi-layer water-blocking design are improved by high-energy electron accelerator, and combined with high-temperature baking for tight bonding, to form a high-efficiency waterproof cable.
It reduces cable costs, improves insulation performance, prevents insulation layer breakdown, reduces electrical system failures caused by poor water permeability, and has good mechanical properties and rodent-proof effect.
Smart Images
Figure CN224067468U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of wire and cable technology, specifically to a new type of environmentally friendly aluminum alloy core waterproof power cable for railway systems. Background Technology
[0002] Waterproof power cables for railway systems with aluminum alloy cores are cables specifically designed for railway systems. They use aluminum alloy as the conductor to replace traditional copper conductors, thereby reducing costs and improving the cable's mechanical properties.
[0003] Traditional railway power cable manufacturing processes typically involve stranding copper conductors, extruding cross-linked polyethylene insulation, extruding a PVC sheath after cabling, using double-layer galvanized steel tape for the armor layer, and PVC for the sheath. This method results in high cable costs. Furthermore, tests using the American ASTM E96 standard show that PVC has a water permeability of 47.6, polyethylene 9.1, cross-linked polyethylene 6.2, while aluminum and lead have zero permeability. These results demonstrate that PVC cannot meet the insulation and sheathing requirements for cables with prolonged water exposure. During operation, poor water permeability leads to decreased insulation resistance, ultimately causing insulation breakdown and resulting in railway electrical system malfunctions, disrupting transportation and causing significant losses. Therefore, to address these issues, a new type of environmentally friendly aluminum alloy core waterproof power cable for railway systems is proposed. Utility Model Content
[0004] The purpose of this invention is to provide a new type of environmentally friendly aluminum alloy core waterproof power cable for railway systems. This addresses the problem of traditional railway power cable manufacturing processes, which typically involve stranding copper conductors, extruding cross-linked polyethylene insulation, extruding a PVC sheath after cabling, using double-layer galvanized steel strips for the armor layer, and using PVC for the sheath. The finished product undergoes final inspection. This type of cable is costly, and testing according to the American ASTM E96 standard shows that PVC has a water permeability of 47.6, polyethylene 9.1, cross-linked polyethylene 6.2, while aluminum, lead, and other metals have a water permeability of 0. The test results demonstrate that PVC cannot meet the insulation and sheath requirements for cables with prolonged water exposure. Such cables, due to their poor water permeability, experience a decrease in insulation resistance during operation, ultimately leading to insulation breakdown and causing malfunctions in the railway electrical system, disrupting transportation and resulting in significant losses.
[0005] To achieve the above objectives, this utility model provides the following technical solution:
[0006] A new type of environmentally friendly aluminum alloy core waterproof power cable for railway systems includes a shaped aluminum alloy conductor for conduction, an insulation layer, a water-blocking filler, a water-blocking wrapping tape, a water-blocking inner lining layer, a metal water-blocking layer, a water-blocking isolation sleeve, galvanized steel wire armor, an outer water-blocking tape, a water-blocking sheath, and an inner water-blocking tape. The shaped aluminum alloy conductor has an inner water-blocking tape on its outer side, an insulation layer on its outer side, a water-blocking filler and a water-blocking wrapping tape on its outer side, a water-blocking inner lining layer on its outer side, a metal water-blocking layer on its outer side, a water-blocking isolation sleeve wrapped around its outer side, a galvanized steel wire armor on its outer side, an outer water-blocking tape on its outer side, and a water-blocking sheath on its outer side. The shaped aluminum alloy conductor has a fan-shaped vertical cross-section, and is made of multiple fan-shaped aluminum alloy conductive wires twisted together.
[0007] As a further optimization of this utility model, the water-blocking filler is evenly distributed on the outer side of the insulation layer and the inner side of the water-blocking tape.
[0008] As a further optimization of this utility model, the metal water-blocking layer is longitudinally wrapped around the outer surface of the water-blocking inner lining layer, and the overlap width of the metal water-blocking layer is 15% of the width of the metal water-blocking layer.
[0009] As a further optimization of this utility model, the metal water-blocking layer is tightly adhered to the outer surface of the water-blocking inner lining layer by high-temperature baking, and the overlapping parts of the metal water-blocking layer are tightly fitted.
[0010] As a further optimization of this utility model, the galvanized steel wire armor is wrapped in a leftward direction, and the total gap between the galvanized steel wires inside the armor is less than the diameter of one steel wire.
[0011] As a further optimization of this utility model, it includes the following steps:
[0012] Step 1: Prepare irregularly shaped aluminum alloy conductors. Traditional round monofilaments are changed into fan-shaped monofilaments by using a specially designed wire drawing die. Then, multiple fan-shaped monofilaments are twisted together to improve the fill factor of the conductor after twisting and reduce the gap area between the conductor monofilaments.
[0013] Step 2: Use a high-energy electron accelerator to irradiate and crosslink polyethylene, so that the polyethylene molecular structure changes from linear to network structure, supporting the insulation layer and covering the outside of the internal water-blocking strip.
[0014] Multiple irregularly shaped aluminum alloy conductors are independently coated by an internal water-blocking band.
[0015] Water-blocking yarn and multi-layer water-blocking tape are selected as the water-blocking filler and water-blocking wrapping of the cable, and are wrapped around the outside of the insulation layer.
[0016] Step 3: Cover the outer surface of the water-blocking tape with a water-blocking inner lining layer, and then cover the outer surface of the water-blocking inner lining layer with a metal water-blocking layer.
[0017] Step 4: The metal water-blocking layer formed by aluminum strip and plastic composite strip is longitudinally wrapped around the surface of the water-blocking inner lining layer in a spiral shape. The overlap rate of the spiral wrapping is not less than 15%. Then, high temperature baking is used to make the overlap tightly adhered.
[0018] Then, the water-blocking isolation sleeve is wrapped around the outer surface of the metal water-blocking layer;
[0019] Step 5: Use galvanized steel wire as the armor layer of the cable to form galvanized steel wire armor;
[0020] Step Six: The galvanized steel wire armored outer surface is successively covered with an external water-blocking tape and a water-blocking sheath to produce a new type of environmentally friendly aluminum alloy core waterproof power cable for railway systems.
[0021] Step 7: Conduct finished product inspection to ensure that the cable meets the performance requirements of railway system power cables.
[0022] Compared with the prior art, the beneficial effects of this utility model are:
[0023] 1. In this utility model, the product is lightweight and low in cost. It has a smaller outer diameter than cables with traditional structures and a lower cost than traditional copper core products. In operation, it can prevent the insulation resistance from dropping due to poor water permeability, which could lead to insulation layer breakdown and cause railway electrical system malfunctions, affecting transportation.
[0024] 2. In this utility model, the cable has a good rodent-proof effect, which can avoid the impact of power outages caused by rodent damage and the cost pressure caused by frequent cable replacement. Attached Figure Description
[0025] Figure 1 This is a schematic diagram of the overall structure of this utility model;
[0026] Figure 2 This is a schematic diagram of the water-blocking isolation sleeve structure of this utility model.
[0027] In the diagram: 1. Irregularly shaped aluminum alloy conductor; 2. Insulation layer; 3. Water-blocking filler; 4. Water-blocking wrapping tape; 5. Water-blocking inner lining layer; 6. Metal water-blocking layer; 7. Water-blocking isolation sleeve; 8. Galvanized steel wire armor; 9. External water-blocking tape; 10. Water-blocking sheath; 11. Internal water-blocking tape. Detailed Implementation
[0028] Please see Figure 1-2This utility model provides a technical solution:
[0029] A new type of environmentally friendly aluminum alloy core waterproof power cable for railway systems includes a shaped aluminum alloy conductor 1 for conductivity, an insulation layer 2, a water-blocking filler 3, a water-blocking wrapping tape 4, a water-blocking inner lining layer 5, a metal water-blocking layer 6, a water-blocking isolation sleeve 7, galvanized steel wire armor 8, an outer water-blocking tape 9, a water-blocking sheath 10, and an inner water-blocking tape 11. The shaped aluminum alloy conductor 1 has an inner water-blocking tape 11 on its outer side. The inner water-blocking tape 11 is surrounded by an insulation layer 2. The insulation layer 2 is surrounded by a water-blocking filler 3 and a water-blocking wrapping tape 4. The water-blocking inner lining layer 5 is surrounded by a water-blocking inner lining layer 5. The metal water-blocking layer 6 is wrapped with... The cable includes a water-blocking isolation sleeve 7, an outer galvanized steel wire armor 8, an outer water-blocking strip 9, and an outer water-blocking sheath 10. The irregularly shaped aluminum alloy conductor 1 has a fan-shaped vertical cross-section, formed by stranding multiple fan-shaped aluminum alloy conductive wires. While ensuring the cable meets design current-carrying requirements, a specially designed drawing die is used to change the traditional conductor structure from circular single wires to fan-shaped single wires, improving the fill factor after stranding. After process improvement, the gap area between conductor single wires is reduced, resulting in a smaller conductor diameter and actual cross-sectional area compared to traditional products. Cables using this structure can save 40-60% in cost compared to traditional copper core cables. This ensures good electrical, mechanical, and environmental performance while also reducing costs.
[0030] As a further implementation of this solution, the insulation layer 2 is cross-linked polyethylene. The cross-linked polyethylene undergoes radiation cross-linking through a high-energy electron accelerator, causing the original molecular structure to change from linear to network structure. After the polyethylene undergoes radiation cross-linking through a high-energy electron accelerator, the original molecular structure changes from linear to network structure, and the molecular gaps are smaller. This not only improves the electrical insulation performance but also significantly improves the waterproof performance of the cable.
[0031] As a further implementation of this solution, the water-blocking filler 3 is a water-blocking yarn, and the water-blocking filler 3 is evenly distributed on the outside of the insulation layer 2 and the inside of the water-blocking wrapping tape 4, which can effectively prevent moisture or humidity from penetrating into the cable through the cable end or sheath surface, thereby playing a waterproof role.
[0032] As a further implementation of this solution, the metal water-blocking layer 6 is a combination of aluminum strip and plastic composite strip. The metal water-blocking layer 6 is longitudinally wrapped around the outer surface of the water-blocking inner lining layer 5. The overlap width of the metal water-blocking layer 6 is 15% of the width of the metal water-blocking layer 6. The metal water-blocking layer 6 is tightly attached to the outer surface of the water-blocking inner lining layer 5 by high temperature baking. The overlap of the metal water-blocking layer 6 is tightly attached, which can not only ensure the original performance of the cable, but also play a waterproof role and ensure that the cable has good bending performance.
[0033] As a further technical solution for implementing this scheme, the galvanized steel wire armor 8 is wrapped in the left direction. The total gap of the galvanized steel wire inside the galvanized steel wire armor 8 is less than the diameter of one steel wire. Using galvanized steel wire as the armor layer of the cable can fully ensure that the cable can withstand high-intensity external impacts and protect the cable insulation from damage caused by accidental impacts during construction or operation, which would affect power supply safety. The use of steel wire armor can also effectively improve the bending performance of the cable and provide good rodent protection.
[0034] As a further technical solution for implementing this scheme, the water-blocking inner lining 5, the water-blocking isolation sleeve 7, and the water-blocking sheath 10 are made of high-density polyethylene. High-density polyethylene has a smaller molecular spacing and better water-blocking performance than other polymer materials, which can ensure the radial waterproof performance of the cable and guarantee the normal operation of the power supply system.
[0035] The manufacturing process of the new environmentally friendly aluminum alloy core waterproof power cable for railway systems is as follows:
[0036] Step 1: Prepare the irregularly shaped aluminum alloy conductor 1. The traditional round monofilament is changed into a fan-shaped monofilament by a specially designed drawing die. Then, multiple fan-shaped monofilaments are twisted together to improve the filling coefficient of the conductor after twisting and reduce the gap area between the conductor monofilaments.
[0037] Step 2: Use a high-energy electron accelerator to irradiate and crosslink polyethylene, so that the polyethylene molecular structure changes from linear to network structure, supporting the insulation layer 2 and covering the outside of the internal water-blocking strip 11.
[0038] Multiple irregularly shaped aluminum alloy conductors 1 are independently coated by an internal water-blocking band 11;
[0039] Water-blocking yarn and multi-layer water-blocking tape are selected as the water-blocking filler 3 and water-blocking wrapping tape 4 of the cable, which are wrapped around the outside of the insulation layer 2.
[0040] Step 3: The outer surface of the water-blocking tape 4 is covered by the water-blocking inner lining layer 5, and the outer surface of the water-blocking inner lining layer 5 is covered by the metal water-blocking layer 6.
[0041] Step 4: The metal water-blocking layer 6 formed by aluminum strip and plastic composite strip is longitudinally wrapped around the surface of the water-blocking inner lining layer 5 in a spiral shape. The overlap rate of the spiral wrapping is not less than 15%. Then, the overlap is tightly bonded by high temperature baking.
[0042] Then the water-blocking isolation sleeve 7 is wrapped around the outer surface of the metal water-blocking layer 6;
[0043] Step 5: Use galvanized steel wire as the armor layer of the cable to form galvanized steel wire armor 8;
[0044] Step 6: The outer surface of the galvanized steel wire armor 8 is successively covered by the external water-blocking tape 9 and the water-blocking sheath 10 to produce a new type of environmentally friendly aluminum alloy core waterproof power cable for railway systems.
[0045] Step 7: Conduct finished product inspection to ensure that the cable meets the performance requirements of railway system power cables.
[0046] This article uses specific examples to illustrate the principles and implementation methods of this utility model. The above examples are only for the purpose of helping to understand the method and core ideas of this utility model. The above description is only a preferred embodiment of this utility model. It should be noted that due to the limitations of textual expression, while there are objectively infinite specific structures, those skilled in the art can make several improvements, modifications, or changes without departing from the principles of this utility model, and can also combine the above technical features in an appropriate manner. These improvements, modifications, changes, or combinations, or the direct application of the concept and technical solution of the utility model to other occasions without modification, should all be considered within the protection scope of this utility model.
Claims
1. A new environmentally friendly waterproof power cable for railway system with aluminum alloy core, characterized in that, The application relates to a water-blocking cable, which comprises a profiled aluminum alloy conductor (1) for electricity conduction, an insulation layer (2), water-blocking filling (3), water-blocking wrapping (4), water-blocking inner lining (5), a metal water-blocking layer (6), a water-blocking isolation sleeve (7), galvanized steel wire armor (8), an outer water-blocking tape (9), a water-blocking sheath (10) and an inner water-blocking tape (11). The profiled aluminum alloy conductor (1) is provided with the inner water-blocking tape (11) on the outer side, the inner water-blocking tape (11) is provided with the insulation layer (2) on the outer side, the insulation layer (2) is provided with the water-blocking filling (3) and the water-blocking wrapping (4) on the outer side, the water-blocking wrapping (4) is provided with the water-blocking inner lining (5) on the outer side, the water-blocking inner lining (5) is provided with the metal water-blocking layer (6) on the outer side, the metal water-blocking layer (6) is wound with the water-blocking isolation sleeve (7) on the outer side, the water-blocking isolation sleeve (7) is provided with the galvanized steel wire armor (8) on the outer side, the galvanized steel wire armor (8) is provided with the outer water-blocking tape (9) on the outer side, and the outer water-blocking tape (9) is provided with the water-blocking sheath (10) on the outer side. The vertical section of the profiled aluminum alloy conductor (1) is fan-shaped, and the profiled aluminum alloy conductor (1) is twisted by a plurality of aluminum alloy conductive wires with fan-shaped vertical sections.
2. The novel eco-friendly aluminum alloy core water-proof power cable for railway system as claimed in claim 1, wherein: The water-blocking filling (3) is uniformly distributed on the outer side of the insulation layer (2) and the inner side of the water-blocking wrapping (4).
3. The novel eco-friendly aluminum alloy core water-proof power cable for railway system as claimed in claim 1, wherein: The metal water-blocking layer (6) is longitudinally wrapped on the outer surface of the water-blocking inner lining (5), and the overlapping width of the metal water-blocking layer (6) is 15% of the width of the metal water-blocking layer (6).
4. The novel eco-friendly aluminum alloy core water-proof power cable for railway system as claimed in claim 1, wherein: The metal water-blocking layer (6) is tightly attached to the outer surface of the water-blocking inner lining (5) through high-temperature baking, and the metal water-blocking layer (6) is tightly attached at the overlapping position.
5. The novel eco-friendly aluminum alloy core water-proof power cable for railway system as claimed in claim 1, wherein: The wrapping direction of the galvanized steel wire armor (8) is leftward, and the total gap of the galvanized steel wire wrapping in the galvanized steel wire armor (8) is less than the wire diameter of one steel wire.