Flexible cable
By designing a buffer layer and insulation layer integrally molded in the high-flexibility cable, the bending stress is dispersed and absorbed, solving the problem of core breakage when the cable is frequently bent, improving the cable's flexibility and resistance to bending fatigue, and making it suitable for high-end applications such as robotics.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-30
- Publication Date
- 2026-04-14
AI Technical Summary
Existing highly flexible cables are prone to core breakage in frequent bending scenarios, leading to insulation cracking or conductor fatigue fracture. They also have insufficient tensile strength, abrasion resistance, and bending resistance, which can easily cause equipment to trip.
Design a flexible cable including a conductor, an insulation layer, a buffer layer, and a sheathing layer. The buffer layer consists of multiple buffer sections evenly distributed circumferentially along the outer wall of the insulation layer, with the buffer sections protruding outwards. Through the integral molding design of the buffer layer and the insulation layer, stress during bending is dispersed and absorbed. The buffer layer is made of an elastic material. The sheathing layer includes a filler layer, a shielding layer, and an outer sheath to enhance flexibility and resistance to bending fatigue.
It significantly improves the bending life and flexibility of cables, avoids short circuits in the core segments, and is safer, making it suitable for high-end applications such as robots that require frequent bending.
Smart Images
Figure CN224123142U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of cable structure technology, specifically to a flexible cable. Background Technology
[0002] With the continuous development of robotics technology, the application scenarios of highly flexible cables are becoming more and more widespread. Currently, highly flexible cables are developing towards higher performance, more environmental protection, and greater safety, and their usage frequency is also increasing, requiring them to adapt to special usage environments involving long-term movement, bending, and winding.
[0003] Currently, the insulation layer of most cables on the market is a smooth cylindrical shape. Due to the lack of stress dispersion structure, the stress is concentrated in a local area when bending. In frequent bending scenarios (such as cables used by industrial robots), core breakage is likely to occur, which can easily lead to insulation layer cracking or conductor fatigue fracture. The tensile strength, wear resistance and bending resistance are relatively low, so core wire short circuits often occur, which can cause equipment to trip and become unusable. Utility Model Content
[0004] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a flexible cable with a longer bending life and higher safety in use.
[0005] To solve the above problems, this utility model provides the following technical solution:
[0006] A flexible cable comprising:
[0007] conductor;
[0008] An insulating layer is formed by covering the outside of the conductor.
[0009] A buffer layer is disposed on the outer wall of the insulating layer and integrally formed with the insulating layer. The buffer layer includes a plurality of buffer portions, which are distributed circumferentially along the outer wall of the insulating layer, and each buffer portion faces at least a portion of the opposite side of the outer wall of the insulating layer to buffer the insulating layer when it is bent.
[0010] A covering layer covers the outside of the buffer layer and abuts against at least the end of the buffer portion.
[0011] In one embodiment, the plurality of buffer portions are distributed circumferentially along the outer wall of the insulating layer, and any two adjacent buffer portions are equally spaced.
[0012] In one embodiment, a trough is formed between any two of the buffer sections.
[0013] In one embodiment, the buffer portion is configured to be hemispherical.
[0014] In one embodiment, the trough is recessed inward to form an arc shape.
[0015] In one embodiment, the number of buffer sections is set between 3 and 8.
[0016] In one embodiment, the covering layer includes a filler layer, a first shielding layer, a second shielding layer, and an outer protective layer. The first shielding layer covers the buffer layer and abuts against the end of each of the buffer portions. The filler layer fills the space between the buffer layer and the first shielding layer and abuts against both the buffer layer and the first shielding layer. The second shielding layer covers the outside of the first shielding layer and abuts against the first shielding layer. The outer protective layer covers the outside of the second shielding layer and abuts against the second shielding layer.
[0017] In one embodiment, the filler layer comprises tensile aramid units and / or high-tensile cords.
[0018] In one embodiment, the conductors are configured as at least two, and all the conductors are twisted together.
[0019] In one embodiment, the conductor comprises a plurality of oxygen-free copper wires and at least one aramid fiber twisted together with the plurality of oxygen-free copper wires.
[0020] The beneficial effects of this utility model are as follows: by designing a buffer layer including multiple buffer portions evenly distributed circumferentially along the outer wall of the insulation layer, and setting the buffer portions to protrude towards the outside of the insulation layer, the stress generated by the insulation layer can be effectively dispersed when the cable is bent. Furthermore, the stress of the insulation layer is absorbed and buffered by the integral molding design of the buffer layer and the insulation layer, so that the cable maintains excellent flexibility while significantly improving flexibility and bending fatigue resistance, greatly increasing the bending life of the cable, thus preventing short circuits in the core segment, and improving safety. It is particularly suitable for high-end application scenarios such as robots that require frequent bending. Attached Figure Description
[0021] Figure 1 This is a cross-sectional schematic diagram of one embodiment of the flexible cable of this utility model;
[0022] Figure 2 for Figure 1 An enlarged schematic diagram of one embodiment of the intermediate conductor;
[0023] Figure 3 This is a side cross-sectional view of one embodiment of the flexible cable of this utility model.
[0024] Figure label:
[0025] 10. Flexible cable; 100. Conductor; 110. Insulation layer; 111. Buffer layer; 1111. Buffer section; 112. Covering layer; 111a. Corrugated groove; 1121. Filling layer; 1122. First shielding layer; 1123. Second shielding layer; 1124. Outer sheath; 11211. Tensile aramid fiber; 11212. High-tensile rope; 1001. Oxygen-free copper wire; 1002. Aramid fiber. Detailed Implementation
[0026] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.
[0027] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.
[0028] Please refer to Figure 1-3 As shown, this embodiment provides a flexible cable 10, which includes: a conductor 100, an insulation layer 110, a buffer layer 111, and a covering layer 112; wherein, the insulation layer 110 covers the outside of the conductor 100; the buffer layer 111 covers the outer wall of the insulation layer 110 and is integrally formed with the insulation layer 110, the buffer layer 111 includes a plurality of buffer portions 1111, the plurality of buffer portions 1111 are distributed circumferentially along the outer wall of the insulation layer 110, and any buffer portion 1111 faces the opposite side of the outer wall of the insulation layer 110, so as to buffer the bent insulation layer 110 when the insulation layer 110 is bent; the covering layer 112 covers the outside of the buffer layer 111 and abuts against at least a portion of the buffer portions 1111.
[0029] like Figure 2As shown, according to the above scheme, it can be understood that this embodiment designs the buffer layer 111 to include multiple buffer portions 1111 evenly distributed circumferentially along the outer wall of the insulation layer 110, and sets the buffer portions 1111 to protrude outward toward the insulation layer 110. This effectively disperses the stress generated by the insulation layer 110 when the cable is bent. The integral molding design of the buffer layer 111 and the insulation layer 110 absorbs and buffers the stress of the insulation layer 110, so that the cable maintains excellent flexibility while significantly improving flexibility and bending fatigue resistance, greatly increasing the bending life of the cable, thus preventing short circuits in the core segments, and improving safety. It is particularly suitable for high-end application scenarios such as robots that require frequent bending.
[0030] like Figure 2 As shown, according to the above scheme, specifically, in this embodiment, the conductor 100 includes multiple oxygen-free copper wires 1001 and at least one aramid fiber 1002 twisted together with the multiple oxygen-free copper wires 1001. The oxygen-free copper wires 1001 are made of 99.99% pure oxygen-free copper, and the oxygen-free copper wires 1001 are set with an ultra-fine structure. The diameter of a single oxygen-free copper wire 1001 is between 0.04 and 0.14 mm. The advantages of this copper wire are strong oxidation resistance, strong cable flexibility, and less prone to core breakage. A single conductor 100 is formed by mixing and twisting with at least one metallized aramid fiber 1002. The oxygen-free copper wires 1001 and the metallized aramid fiber 1002 are twisted alternately at a helix angle of 30°±5°, and the number of all oxygen-free copper wires 1001 is between 50 and 300.
[0031] Understandably, the use of metallized aramid fibers, a newly introduced conductive material, to twist together with oxygen-free copper wire not only retains the original materials' strength, light weight, and fire resistance, but also acquires the properties of metal—conductivity. This allows it to replace traditional copper wire, stainless steel wire, aluminum wire, etc. The metallized aramid fibers have high strength, greater than 28 g / denier, which is 5-6 times that of high-quality steel. Their modulus is 2-3 times that of steel or glass fiber, and their toughness is twice that of steel, while their weight is only 1 / 5 that of steel.
[0032] Preferably, in this embodiment, the cross-sectional area of a single oxygen-free copper wire 1001 is 0.8 mm², and the stranding pitch is 12 mm. Under the same cross-sectional area, the thinner the copper wire, the more wires there are, and the stronger the flexibility of the cable. This design takes into account both the conductivity and flexibility of the conductor 100.
[0033] Please refer to Figure 1-2As shown, preferably, the insulation layer 110 is made of high-temperature resistant, high-pressure resistant and corrosion-resistant fluoroplastic and is coated on the outside of the conductor 100 by extrusion process, with a thickness of 0.5mm. Its outer wall is formed by molding to form a buffer layer 111. The buffer layer 111 is integrally formed with the insulation layer 110 and is made of elastic silicone material. It includes multiple independent hemispherical buffer parts 1111. The buffer parts 1111 have a diameter of 2mm and a height of 0.8mm and are arranged in a 5mm×5mm rectangular array in the gaps between the protrusions of the insulation layer 110. It can be understood that when the cable is bent, the buffer parts 1111 absorb the local stress on the insulation layer 110 through elastic deformation.
[0034] Preferably, the number of buffer sections 1111 is set between 3 and 8.
[0035] Please refer to Figure 1-2 As shown, preferably, the buffer layer 111 adopts a ring array design, with multiple buffer sections 1111 distributed circumferentially along the outer wall of the insulation layer 110. The multiple buffer sections 1111 are arranged around the outer wall of the insulation layer 110, and any two adjacent buffer sections 1111 are equally spaced. This arrangement ensures that the spacing between any two adjacent buffer sections 1111 is exactly the same, thereby ensuring that the cable can obtain a uniform stress distribution when bending. Specifically, taking a 5mm diameter cable as an example, eight buffer sections 1111 are usually set on the outer wall of the insulation layer 110, and the center angle between adjacent buffer sections 1111 is precisely controlled at 45°, with a spacing arc length of about 1.96mm. This geometric arrangement optimizes the stress dispersion effect. In practical applications, when the cable is bent and deformed, the ring array of buffer sections 1111 can act individually or in concert to absorb stress in one or more directions, effectively preventing damage to the insulation layer 110 caused by local stress concentration. Meanwhile, the evenly spaced buffer sections 1111 can form a continuous support surface under torsional conditions, significantly reducing the relative slippage between the insulation layer 110 and the sheathing layer 112. Tests show that the cable with this design has a significantly longer bending life under the same working conditions than the cable with a non-uniformly arranged buffer layer 111, fully demonstrating the technical advantages of this preferred solution. This structural design meets the stringent requirements of robot cables for flexibility and durability; under normal conditions, it can withstand 10 to 15 million bends without core breakage or cracking.
[0036] like Figure 2As shown, preferably, the shape of the buffer portion 1111 is hemispherical; these different shapes of buffer portions 1111 each have their own characteristics: the hemispherical buffer portion 1111 can achieve gradual stress transmission through the smooth curved surface, which is suitable for small vibration or bending conditions; in some other embodiments, a cylindrical buffer portion 1111 can also be provided, which provides stable support performance with its larger contact area, especially suitable for occasions requiring pressure resistance; in practical applications, the most suitable shape can be selected according to the specific use scenario of the cable - for example, the hemispherical buffer layer 111 is suitable for the joint of industrial robots to obtain all-round flexibility, while the cylindrical buffer layer 111 can be selected for fixed wiring sections to enhance radial support. Compared with the traditional single-shape design, this multi-form selection of buffer layer 111 solution can improve the fatigue life of the cable and reduce bending resistance.
[0037] like Figure 2 As shown, preferably, a trough 111a is formed between any two buffer portions 1111, and a regular wavy surface profile is formed by setting equally spaced recessed areas between any two adjacent buffer portions 1111. Specifically, when a hemispherical buffer portion 1111 is used, the depth of the trough 111a between adjacent buffer portions 1111 is controlled at 0.2-0.5mm, and the groove width is 1-2mm, forming a smoothly transitioned U-shaped groove structure. In other embodiments, if a cylindrical buffer portion 1111 is used, the trough 111a presents a regular rectangular cross section. The buffer layer 111 designed in this way further improves the bending life of the cable.
[0038] Preferably, the trough 111a is concave inward to form an arc shape. When the cable is subjected to radial pressure, the arc-shaped trough will produce progressive elastic deformation, thus more easily absorbing the impact force brought about by bending.
[0039] Please refer to Figure 1 and Figure 3 As shown, preferably, the covering layer 112 includes a filling layer 1121, a first shielding layer 1122, a second shielding layer 1123, and an outer protective layer 1124. The first shielding layer 1122 covers the buffer layer 111 and abuts against the end of each buffer portion 1111. The first shielding layer 1122 adopts a high-density woven aluminum mesh or polyester film structure, and its inner surface forms a surface contact with the top of each buffer portion 1111 of the buffer layer 111 to ensure the continuity of electromagnetic shielding. The filling layer 1121 fills the space between the buffer layer 111 and the first shielding layer 1122 and abuts against the buffer layer 111 and the first shielding layer 1122. The second shielding layer 1123 covers the outside of the first shielding layer 1122 and abuts against the first shielding layer 1122. The outer protective layer 1124 covers the outside of the second shielding layer 1123 and abuts against the second shielding layer 1123.
[0040] like Figure 1As shown, the filling layer 1121 is made of tensile aramid fiber 11211 and high-tensile rope 11212, making the wire more tensile, bending-resistant, and highly flexible, achieving high swing and bending performance. By filling the gap between the concave-convex structure of the buffer layer 111 and the first shielding layer 1122, it achieves the dual functions of stress buffering and structural support. The second shielding layer 1123 is made of tin-plated copper, forming a double guarantee of electromagnetic shielding with the first shielding layer 1122. The outermost layer is made of modified nitrile elastomer material and is coated by extrusion molding process, with its inner surface closely attached to the second shielding layer 1123. This layered structural design not only ensures the close cooperation between the functional layers, but also, through the synergistic effect of the buffer part 1111, the filling layer 1121, and the shielding layer, enables the product to maintain excellent flexibility while possessing excellent electromagnetic interference protection capabilities.
[0041] like Figure 1 As shown, preferably, there are at least two conductors 100, and all conductors 100 are twisted together; in this embodiment, there are four conductors 100, two conductors 100 are twisted together to form a double conductor 100 core, and another conductor 100 is twisted together to form another double conductor 100 core, and the two cores are twisted together to form a four conductor 100 core.
[0042] In summary, this utility model provides a flexible cable. By designing a buffer layer including multiple buffer portions evenly distributed circumferentially along the outer wall of the insulation layer, and setting the buffer portions to protrude outwards from the insulation layer, the stress generated by the insulation layer can be effectively dispersed when the cable is bent. Furthermore, the integral molding design of the buffer layer and the insulation layer absorbs and buffers the stress of the insulation layer. This allows the cable to maintain excellent flexibility while significantly improving its flexibility and resistance to bending fatigue, greatly extending the bending life of the cable. This prevents short circuits in the core segments, resulting in higher safety. It is particularly suitable for high-end applications such as robots that require frequent bending.
[0043] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.
Claims
1. A flexible cable, characterized by, The utility model relates to a cable, comprising: a conductor; an insulation layer covering the conductor; a buffer layer provided on the outer wall of the insulation layer and integrally formed with the insulation layer, the buffer layer comprising a plurality of buffer portions, the plurality of buffer portions being distributed circumferentially along the outer wall of the insulation layer, and any buffer portion facing at least one opposite side of the outer wall of the insulation layer to buffer the insulation layer being bent; a covering layer covering the buffer layer and at least abutting against the end of the buffer portion.
2. The flexible cable of claim 1, wherein: The plurality of buffer portions are distributed circumferentially along the outer wall of the insulation layer, and any two adjacent buffer portions are equally spaced.
3. The flexible cable according to claim 1 or 2, characterized in that: A trough is formed between any two buffer portions.
4. The flexible cable of claim 1 or 2, wherein: The shape of the buffer portion is semispherical.
5. The flexible cable of claim 3, wherein: The trough is inwardly recessed to form an arc shape.
6. The flexible cable of claim 2, wherein: The number of the buffer portions ranges from 3 to 8.
7. The flexible cable of claim 1, wherein: The covering layer comprises a filling layer, a first shielding layer, a second shielding layer and an outer protective layer, the first shielding layer covering the buffer layer and abutting against the end of each buffer portion, the filling layer being filled between the buffer layer and the first shielding layer and abutting against each other, the second shielding layer covering the outer side of the first shielding layer and abutting against the first shielding layer, and the outer protective layer covering the outer side of the second shielding layer and abutting against the second shielding layer.
8. The flexible cable of claim 7, wherein: The filling layer comprises a tensile aramid unit and / or a high-tension rope.
9. The flexible cable of claim 1, wherein: The conductor is provided as at least two, and all the conductors are twisted with each other.
10. The flexible cable of claim 1 or 9, wherein: The conductor comprises a plurality of oxygen-free copper wires and at least one aramid fiber twistedly connected with the plurality of oxygen-free copper wires.