Halogen-free cable with anti-cracking structure
By introducing a corrugated elastomer layer and reinforcement into halogen-free cables, the problem of traditional halogen-free cables being prone to cracking under low temperature, bending, or mechanical stress is solved, thereby improving the crack resistance and tensile strength of the cables, extending their service life, and ensuring safety.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-21
- Publication Date
- 2026-04-03
AI Technical Summary
Traditional halogen-free cables are prone to cracking under low temperature, bending, or mechanical stress, which leads to a decrease in insulation performance and poses safety hazards.
The crack-resistant layer is composed of a corrugated elastomer layer and reinforcing members. The axial corrugated structure provides expansion space and absorbs mechanical stress. The sheath layer and the crack-resistant layer are fused together through a co-extrusion process to eliminate the interlayer interface.
It effectively inhibits crack formation, extends service life, improves tensile strength, prevents radial cracking, and ensures the stability and safety of cables in complex environments.
Smart Images
Figure CN224082224U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of wire and cable technology, and specifically discloses a halogen-free cable with a crack-resistant structure. Background Technology
[0002] Wires and cables are wire products used to transmit electrical (magnetic) energy, information, and realize the conversion of electromagnetic energy. In a broad sense, wires and cables are also simply referred to as cables. In a narrow sense, cables refer to insulated cables, which can be defined as: an assembly consisting of one or more insulated conductors, and their respective possible coverings, overall protective layers, and outer sheaths. Cables may also have additional uninsulated conductors.
[0003] Traditional halogen-free cables, because they do not contain halogen flame retardants, often use polyolefin compounds as sheath materials. Although environmentally friendly, they have poor flexibility and are prone to cracking under low temperature, bending, or mechanical stress, resulting in a decrease in insulation performance. In existing technologies, the interface between the sheath and the insulation layer is prone to micro-cracks due to thermal expansion and contraction or external forces, which poses a safety hazard in the long term. Utility Model Content
[0004] This invention proposes a halogen-free cable with a crack-resistant structure. The corrugated elastomer layer provides expansion and contraction space when the cable is bent or subjected to external force through the periodic distribution of axial corrugations with peaks / troughs, absorbing mechanical stress and inhibiting crack formation. The sheath layer and the crack-resistant layer are fused together through a co-extrusion process, eliminating the traditional interlayer interface and avoiding interlayer peeling caused by thermal expansion and contraction or external force, thus extending the service life.
[0005] This utility model is implemented as follows: a halogen-free cable with a crack-resistant structure includes a conductor, an insulation layer, a filling layer, a crack-resistant layer, and a sheath layer arranged sequentially from the inside to the outside.
[0006] The crack-resistant layer consists of a corrugated elastomer layer and reinforcing members;
[0007] The corrugated elastomer layer is wrapped around the outer surface of the insulation layer, and its cross-section has a periodic corrugated structure with the corrugation direction parallel to the cable axis.
[0008] The reinforcing member is a high-strength fiber or metal wire, which is embedded in the trough of the corrugated elastomer layer in a spiral winding manner;
[0009] The sheath layer and the crack-resistant layer are fused together.
[0010] As a preferred embodiment of the halogen-free cable with a crack-resistant structure according to this utility model, the material of the corrugated elastomer layer is one of thermoplastic elastomer, thermoplastic polyurethane, or silicone rubber.
[0011] As a preferred embodiment of the halogen-free cable with a crack-resistant structure according to this utility model, the reinforcing member is made of one or more combinations of aramid fiber, glass fiber, polyester fiber, or tin-plated copper wire.
[0012] As a preferred embodiment of the halogen-free cable with anti-crack structure of this utility model, the sheath layer is made of halogen-free flame-retardant polyolefin with a thickness of 1.0-2.0mm. The outer surface of the sheath layer is provided with anti-slip texture, the depth of the anti-slip texture is 0.1-0.3mm, and the texture direction is perpendicular to the cable axis.
[0013] As a preferred embodiment of the halogen-free cable with a crack-resistant structure according to this utility model, the filling layer is composed of a water-blocking halogen-free material, including a water-blocking yarn wrapping layer and a flame-retardant tape wrapping layer. The water-blocking yarn wrapping layer is made of polyester fiber yarn coated with superabsorbent resin, and the flame-retardant tape wrapping layer is made of halogen-free flame-retardant polypropylene tape.
[0014] As a preferred embodiment of the halogen-free cable with a crack-resistant structure according to this utility model, the insulation layer is made of cross-linked polyolefin material with a thickness of 0.5-1.2 mm.
[0015] As a preferred embodiment of the halogen-free cable with a crack-resistant structure according to this utility model, a shielding layer is provided between the filling layer and the crack-resistant layer, and the shielding layer is composed of longitudinally wrapped aluminum-plastic composite tape.
[0016] The beneficial effects of this utility model are:
[0017] The corrugated elastomer layer provides expansion and contraction space when the cable is bent or subjected to external force through the periodic distribution of axial corrugated peaks / troughs, absorbing mechanical stress and preventing stress concentration in the sheath layer, thereby inhibiting crack formation. The reinforcing fiber / metal wire, spirally wound, is embedded in the corrugated troughs to form a constraint, limiting excessive deformation of the corrugated elastomer layer, improving tensile strength, and preventing radial crack propagation. The sheath layer and the crack-resistant layer are fused together through a co-extrusion process, eliminating the traditional interlayer interface and avoiding interlayer delamination caused by thermal expansion and contraction or external force, thus extending service life. The sheath layer, insulation layer, and filler layer are made of halogen-free flame-retardant materials, which do not release toxic gases when burning. Furthermore, through the combination of flame-retardant polyolefins, water-blocking yarns, and other materials, environmental protection and flame-retardant and water-blocking functions are achieved. The shielding layer enhances the stability of the cable in complex electromagnetic environments. Attached Figure Description
[0018] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn to scale.
[0019] Figure 1 This is a structural diagram of the present invention;
[0020] Figure 2 This is a cross-sectional structural diagram of the filling layer of this utility model;
[0021] Figure 3 This is a three-dimensional view of the overall external structure of this utility model.
[0022] The markings in the diagram are: 1. Conductor; 2. Insulation layer; 3. Filler layer; 4. Corrugated elastomer layer; 5. Reinforcing element; 6. Sheath layer; 7. Water-blocking yarn wrapping layer; 8. Flame-retardant tape wrapping layer; 9. Shielding layer; 10. Anti-slip texture. Detailed Implementation
[0023] The present invention will be further described below with reference to the accompanying drawings and specific embodiments to aid in understanding its content. Unless otherwise specified, the methods used in this invention are conventional methods; the raw materials and apparatus used, unless otherwise specified, are conventional commercially available products.
[0024] Please see Figure 1-3 A halogen-free cable with a crack-resistant structure includes a conductor 1, an insulation layer 2, a filling layer 3, a crack-resistant layer, and a sheath layer 6 arranged sequentially from the inside to the outside.
[0025] The crack-resistant layer consists of a corrugated elastomer layer 4 and a reinforcing member 5;
[0026] A corrugated elastomer layer 4 is wrapped around the outer surface of the insulation layer 2. Its cross-section has a periodic corrugated structure, and the corrugation direction is parallel to the cable axis.
[0027] The reinforcing member 5 is made of high-strength fiber or metal wire, which is embedded in the trough of the corrugated elastomer layer 4 in a spiral winding manner;
[0028] Sheath layer 6 is fused with crack-resistant layer.
[0029] In this embodiment: the corrugated elastomer layer 4 provides expansion space when the cable is bent or subjected to external force through the periodic distribution of axial corrugated peaks / troughs, absorbs mechanical stress, and avoids stress concentration in the sheath layer 6, thereby inhibiting crack generation. The reinforcing member 5 has spirally wound fibers / metal wires embedded in the corrugated troughs to form constraints, limit excessive deformation of the corrugated elastomer layer 4, improve tensile strength, and prevent radial crack propagation. The sheath layer 6 is fused with the anti-crack layer. The sheath layer 6 and the corrugated elastomer layer 4 are fused through a co-extrusion process, eliminating the traditional interlayer interface and avoiding interlayer delamination caused by thermal expansion and contraction or external force, thus extending service life. The sheath layer 6, insulation layer 2, and filling layer 3 are made of halogen-free flame-retardant material, which does not release toxic gases when burning. Furthermore, the combination of flame-retardant polyolefin, water-blocking yarn, and other materials achieves environmental protection and flame-retardant and water-blocking functions. The shielding layer 9 improves the stability of the cable in complex electromagnetic environments.
[0030] As a technical optimization of this utility model, the material of the corrugated elastomer layer 4 is one of thermoplastic elastomer, thermoplastic polyurethane or silicone rubber.
[0031] In this embodiment, thermoplastic elastomer (TPE), thermoplastic polyurethane (TPU), or silicone rubber is selected as the material for the corrugated elastomer layer. Utilizing its high elastic modulus and weather resistance, it absorbs energy through corrugated deformation under stress, while adapting to a temperature range of -40℃ to 120℃, avoiding low-temperature brittleness or high-temperature softening, and improving environmental adaptability.
[0032] As a technical optimization of this utility model, the reinforcing member 5 is made of one or more combinations of aramid fiber, glass fiber, polyester fiber or tin-plated copper wire.
[0033] In this embodiment, high-strength materials such as aramid fibers and glass fibers are embedded in the corrugated troughs through spiral winding. The tensile strength of the fibers is used to limit the lateral deformation of the corrugated layer, forming a "directional constraint" effect, which blocks the crack from spreading along the radial path and improves the tensile strength.
[0034] As a technical optimization of this utility model, the sheath layer 6 is made of halogen-free flame-retardant polyolefin with a thickness of 1.0-2.0mm. The outer surface of the sheath layer 6 is provided with anti-slip texture 10, the depth of which is 0.1-0.3mm, and the texture direction is perpendicular to the cable axis.
[0035] In this embodiment: the halogen-free flame-retardant polyolefin sheath layer eliminates interfacial stress through co-extrusion welding. The anti-slip texture 10 on the outer surface of the sheath layer 6 in the vertical axis increases the surface friction coefficient and prevents slippage and detachment during cable laying, thus balancing flame-retardant safety and construction efficiency.
[0036] As a technical optimization of this utility model, the filling layer 3 is composed of water-blocking halogen-free material, including a water-blocking yarn wrapping layer 7 and a flame-retardant tape wrapping layer 8. The water-blocking yarn wrapping layer 7 is made of polyester fiber yarn coated with super absorbent resin, and the flame-retardant tape wrapping layer 8 is made of halogen-free flame-retardant polypropylene tape.
[0037] In this embodiment: the water-blocking yarn wrapping layer uses super-absorbent resin to expand and block the gaps when it comes into contact with water, resulting in a high water-blocking rate. The flame-retardant polypropylene tape is wrapped in two layers to form a dense carbonized layer, which slows down the spread of flames and achieves synergistic protection of water blocking and flame retardancy.
[0038] As a technical optimization of this utility model, the insulating layer 2 is a cross-linked polyolefin material with a thickness of 0.5-1.2mm.
[0039] In this embodiment: the insulating layer 2 is a cross-linked polyolefin material with a thickness of 0.5-1.2 mm. The cross-linked polyolefin ensures the insulation stability.
[0040] As a technical optimization of this utility model, a shielding layer 9 is provided between the filling layer 3 and the crack-resistant layer, and the shielding layer 9 is composed of aluminum-plastic composite strips wrapped longitudinally.
[0041] In this embodiment, the longitudinally wrapped shielding layer of aluminum-plastic composite tape is bonded with conductive adhesive to form a continuous conductive surface. Combined with the lead-out wire to guide the induced current, the impact of electromagnetic interference on signal transmission is reduced, and the application range of the cable in industrial automation scenarios is expanded.
[0042] The working principle and usage process of this utility model: The corrugated elastomer layer 4 provides expansion and contraction space when the cable is bent or subjected to external force through the periodic distribution of axial corrugated peaks / valleys, absorbing mechanical stress and avoiding stress concentration in the sheath layer 6, thereby inhibiting crack generation. The reinforcing member 5 has spirally wound fibers / metal wires embedded in the corrugated valleys to form constraints, limiting excessive deformation of the corrugated elastomer layer 4, improving tensile strength, and preventing radial crack propagation. The sheath layer 6 is fused with the crack-resistant layer. The sheath layer 6 and the corrugated elastomer layer 4 are fused through a co-extrusion process, eliminating the traditional interlayer interface and avoiding interlayer peeling caused by thermal expansion and contraction or external force, thus extending service life. The sheath layer 6, insulation layer 2, and filling layer 3 are made of halogen-free flame-retardant material, which does not release toxic gases when burning. Furthermore, through the combination of flame-retardant polyolefin, water-blocking yarn, and other materials, environmental protection and flame-retardant and water-blocking functions are achieved. The shielding layer 9 improves the stability of the cable in complex electromagnetic environments.
[0043] In the description of this utility model, it should be understood that the terms "left", "right", "up", "down", "top", "bottom", "front", "back", "inner", "outer", "back", "middle", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.
[0044] However, the above description is only a specific embodiment of this utility model and should not be construed as limiting the scope of implementation of this utility model. Therefore, any substitution of equivalent components or equivalent changes and modifications made in accordance with the scope of protection of this utility model should still fall within the scope of the claims of this utility model.
Claims
1. A halogen-free cable with a crack-resistant structure, characterized in that: It includes, from the inside out, a conductor (1), an insulation layer (2), a filling layer (3), a crack-resistant layer, and a sheath layer (6); The crack-resistant layer is composed of a corrugated elastomer layer (4) and a reinforcing member (5); The corrugated elastomer layer (4) covers the outer surface of the insulation layer (2), and its cross-section has a periodic corrugated structure with the corrugation direction parallel to the cable axis. The reinforcing member (5) is a high-strength fiber or metal wire, which is embedded in the trough of the corrugated elastomer layer (4) in a spiral winding manner; The sheath layer (6) is fused to the crack-resistant layer.
2. A halogen-free cable with a crack-resistant structure according to claim 1, characterized in that: The corrugated elastomer layer (4) is made of one of thermoplastic elastomer, thermoplastic polyurethane or silicone rubber.
3. A halogen-free cable with a crack-resistant structure according to claim 1, characterized in that: The reinforcing member (5) is made of one or more of the following materials: aramid fiber, glass fiber, polyester fiber, or tin-plated copper wire.
4. A halogen-free cable with a crack-resistant structure according to claim 1, characterized in that: The sheath layer (6) is made of halogen-free flame-retardant polyolefin with a thickness of 1.0-2.0 mm. The outer surface of the sheath layer (6) is provided with anti-slip texture (10) with a depth of 0.1-0.3 mm and the texture direction is perpendicular to the cable axis.
5. A halogen-free cable with a crack-resistant structure according to claim 1, characterized in that: The filling layer (3) is made of water-blocking halogen-free material, including a water-blocking yarn wrapping layer (7) and a flame-retardant tape wrapping layer (8). The water-blocking yarn wrapping layer (7) is made of polyester fiber yarn coated with super absorbent resin, and the flame-retardant tape wrapping layer (8) is made of halogen-free flame-retardant polypropylene tape.
6. A halogen-free cable with a crack-resistant structure according to claim 1, characterized in that: The insulating layer (2) is a cross-linked polyolefin material with a thickness of 0.5-1.2 mm.
7. A halogen-free cable with a crack-resistant structure according to claim 1, characterized in that: A shielding layer (9) is provided between the filling layer (3) and the crack-resistant layer. The shielding layer (9) is made of aluminum-plastic composite strip wrapped longitudinally.