High-tensile multi-layer stranded power cable

Abstract

The utility model belongs to the field of power cables, and particularly relates to a high-tensile multi-layer stranded power cable, which comprises an inner-layer conductor. The surface of the inner-layer conductor is sleeved with an outer-layer stranded layer, the surface of the outer-layer stranded layer is sleeved with an interlayer buffer layer, the surface of the interlayer buffer layer is provided with a reinforced braid layer, and the surface of the reinforced braid layer is sleeved with a sheath layer; the inner-layer conductor is formed by twisting metal wires, the outer-layer twisting layer is formed by spirally winding metal wires on the outer surface of the inner-layer conductor, the twisting direction of the outer-layer twisting layer is opposite to that of the inner-layer conductor, the interlayer buffer layer covers the surface of the outer-layer twisting layer, and the sheath layer covers the interlayer buffer layer; through the collaborative structural design of the inner-layer conductor, the outer-layer stranded layer, the interlayer buffer layer, the reinforced braid layer and the sheath layer, the comprehensive improvement of the tensile strength, the bending fatigue life and the lightweight level of the cable is realized, the problems of poor mechanical strength and dynamic adaptability are solved, and the economical efficiency and the engineering applicability of the cable are improved.

Description

Technical Field

[0001] This utility model relates to the field of power cables, specifically a high tensile strength multilayer stranded power cable. Background Technology

[0002] With the rapid development of new energy power generation (such as offshore wind power and photovoltaic power stations), industrial automation equipment, and mobile power supply scenarios, power cables need to operate stably for a long time under complex mechanical stress environments. Traditional cable structures mostly focus on optimizing electrical performance, but their mechanical strength and dynamic adaptability have significant shortcomings.

[0003] In the prior art, such as in publication number CN203444850U, a power cable is disclosed, which includes an outer sheath and a cable core, with a flame-retardant layer, an insulation layer, and a shielding layer disposed between the outer sheath and the cable core. This invention effectively solves the problems of existing power cables being prone to leakage and short circuits, having poor safety performance, and short service life.

[0004] Although the aforementioned patent achieves the effect of preventing leakage and short circuit through a multi-layer protection structure, the cable is poor in terms of mechanical strength and dynamic adaptability, and is prone to mechanical stress damage. Therefore, a high tensile strength multi-layer stranded power cable is proposed to address the above problems. Utility Model Content

[0005] To overcome the shortcomings of existing technologies, such as poor mechanical strength and dynamic adaptability, and susceptibility to mechanical stress damage, this utility model proposes a high-tensile multilayer stranded power cable.

[0006] The technical solution adopted by this utility model to solve its technical problem is as follows: The high tensile strength multilayer stranded power cable of this utility model includes an inner conductor; an outer stranded layer is sleeved on the surface of the inner conductor, an interlayer buffer layer is sleeved on the surface of the outer stranded layer, a reinforcing braid layer is provided on the surface of the interlayer buffer layer, and a sheath layer is sleeved on the surface of the reinforcing braid layer.

[0007] The inner conductor is formed by stranding metal wires, the outer stranded layer is formed by spirally winding metal wires around the outer surface of the inner conductor and the stranding direction is opposite to that of the inner conductor, the interlayer buffer layer covers the surface of the outer stranded layer, and the sheath layer covers the outside of the interlayer buffer layer.

[0008] Preferably, the sheath layer has an embedded reinforcing braided layer, which is a mesh structure with a warp braid density greater than the weft braid density and completely covers the outer surface of the interlayer buffer layer.

[0009] Preferably, the metal wires of the outer stranded layer are spirally wound in alternating directions, with adjacent spiral layers having opposite stranding directions.

[0010] Preferably, the mesh structure of the reinforcing braided layer is integrally integrated with the sheath layer through a melt-embedding process, and is located entirely on the radial inner side of the sheath layer.

[0011] Preferably, the interlayer buffer layer is attached to the surface of the outer stranded layer by a spraying process, and the sheath layer is coated with the interlayer buffer layer by a curing process to form a continuous interface with it.

[0012] Preferably, the inner conductor is twisted in a right-hand direction, and the outermost spiral of the outer stranded layer is wound in a left-hand direction.

[0013] The advantages of this utility model are:

[0014] 1. This utility model achieves a comprehensive improvement in the tensile strength, bending fatigue life, and lightweight level of the cable through the synergistic structural design of the inner conductor, outer stranded layer, interlayer buffer layer, reinforcing braided layer, and sheath layer. It solves the problems of poor mechanical strength and dynamic adaptability, and improves the economic efficiency and engineering applicability of the cable. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0017] Figure 2 This is a schematic diagram of the outer stranded layer and interlayer buffer layer structure of this utility model;

[0018] Figure 3 This is a schematic diagram of the sheath layer and reinforcing braided layer structure of this utility model;

[0019] Figure 4 This is a schematic diagram of the disassembled structure of this utility model.

[0020] In the diagram: 1. Inner conductor; 2. Outer stranded layer; 3. Interlayer buffer layer; 4. Sheath layer; 5. Reinforcing braid layer. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present utility model.

[0022] Please see Figures 1-4 As shown, a high tensile strength multilayer stranded power cable includes an inner conductor 1; an outer stranded layer 2 is sleeved on the surface of the inner conductor 1, an interlayer buffer layer 3 is sleeved on the surface of the outer stranded layer 2, a reinforcing braided layer 5 is provided on the surface of the interlayer buffer layer 3, and a sheath layer 4 is sleeved on the surface of the reinforcing braided layer 5; the inner conductor 1 is formed by stranding metal wires, the outer stranded layer 2 is formed by spirally winding metal wires on the outer surface of the inner conductor 1 with the stranding direction opposite to that of the inner conductor 1, the interlayer buffer layer 3 covers the surface of the outer stranded layer 2, and the sheath layer 4 covers the outside of the interlayer buffer layer 3;

[0023] During operation, multiple high-conductivity metal wires are first twisted in a right-hand direction to form an inner conductor 1. Then, high-strength metal alloy wires are spirally wound in a left-hand direction on its outer surface to form an outer stranded layer 2. The reverse twisting design of the inner and outer layers ensures that tensile stress is evenly distributed along the conductor axis. Next, a nano-ceramic particle modified elastic material is uniformly coated on the surface of the outer stranded layer 2 using an electrostatic spraying process to form an interlayer buffer layer 3 with controllable thickness. After thermosetting, this coating adheres tightly to the outer stranded layer 2, effectively absorbing interlayer friction generated during dynamic bending. Subsequently, a reinforcing braided layer 5 made of polyester fiber and glass fiber is covered on the outer surface of the interlayer buffer layer 3. An asymmetric braiding process with dense weft and loose weft is used to directionally enhance the longitudinal tensile strength. The reinforcing braided layer 5 is integrated with the thermoplastic polyurethane sheath layer 4 through a melt-embedding process, ensuring that the reinforcing braided layer 5 is completely embedded in the radial inner side of the sheath layer 4 with no gaps at the interface. Finally, the sheath layer 4 is molded to form a continuous cured interface with the interlayer buffer layer 3, blocking external mechanical impact from being transmitted to the inner conductor. During implementation, the alternating twisting direction of the inner conductor 1 and the outer stranded layer 2, the asymmetric density distribution of the reinforcing braided layer 5, and the elastic energy absorption characteristics of the interlayer buffer layer 3 work together to give the finished cable high tensile strength, small bending radius, and lightweight characteristics.

[0024] Furthermore, the sheath layer 4 is embedded with a reinforcing braided layer 5, which has a mesh structure with a warp braid density greater than the weft braid density, and completely wraps the outer surface of the interlayer buffer layer 3.

[0025] During operation, the sheath layer 4 contains an embedded reinforcing braided layer 5, with a warp braid density greater than the weft braid density, completely encasing the interlayer buffer layer 3. This asymmetric density mesh structure enhances longitudinal tensile strength through dense warp weaving and retains lateral flexibility through loose weft weaving, ensuring that stress is evenly distributed along the warp fibers when the cable is under tension, thus increasing tensile strength and preventing an increase in bending radius due to excessive weft rigidity. In practice, polyester and glass fiber hybrid braided yarns are used. The warp yarn tension is adjusted on the braiding machine to form a mesh reinforcing braided layer 5 with a density gradient distribution. Subsequently, the reinforcing braided layer 5 is pre-placed in the extrusion mold of the sheath layer 4 through a melt-embedding process, allowing the molten sheath material to penetrate the mesh of the braided layer and solidify, achieving a seamless bond between the sheath layer 4 and the reinforcing braided layer 5.

[0026] Furthermore, the metal wires of the outer stranded layer 2 are spirally wound in alternating directions, with the stranding directions of adjacent spiral layers being opposite;

[0027] During operation, the metal wires of the outer stranded layer 2 are spirally wound in alternating directions, with adjacent spiral layers twisted in opposite directions. This alternating winding direction design counteracts the torque accumulation caused by unidirectional twisting, allowing the stress in each stranded layer to mutually restrain each other during dynamic bending of the cable, suppressing interlayer slippage and extending fatigue life. Specifically, the first layer of metal wire is wound in a right-hand spiral direction on the outer surface of the inner conductor 1. The second layer is then wound in a left-hand spiral direction and offset to cover the gaps in the first layer. This alternation is repeated until a preset number of layers are reached, ultimately resulting in the outermost spiral direction being opposite to that of the inner conductor 1, forming a self-balancing stranded structure.

[0028] Furthermore, the interlayer buffer layer 3 is attached to the surface of the outer stranded layer 2 by a spraying process, and the sheath layer 4 is coated with the interlayer buffer layer 3 by a curing process to form a continuous interface with it.

[0029] During operation, the interlayer buffer layer 3 is attached to the outer stranded layer 2 via a spraying process, and the sheath layer 4 is coated with the interlayer buffer layer 3 via a curing process to form a continuous interface. The spraying process ensures that the interlayer buffer layer 3 evenly covers the uneven surfaces of the outer stranded layer 2, fills the gaps between the metal wires, and reduces local stress concentration; the curing process allows the molecular chains at the interface between the sheath layer 4 and the interlayer buffer layer 3 to interpenetrate, enhancing interlayer adhesion and preventing interface delamination under dynamic working conditions. In specific implementation, an electrostatic spraying device is used to atomize and adsorb nano-ceramic modified silicone rubber onto the surface of the outer stranded layer 2, which is then cured with hot air to form the interlayer buffer layer 3. Subsequently, the sheath layer 4 is extruded over the interlayer buffer layer 3 and cured in an oven tunnel, causing the interface between the sheath layer 4 and the interlayer buffer layer 3 to form a chemical cross-link.

[0030] Working principle: The inner conductor 1 serves as the conductive core, formed by stranding highly conductive metal wires. Its right-hand stranded structure provides basic conductivity and inner layer torsional stiffness. The outer stranded layer 2 uses metal wires spirally wound in the opposite direction to the inner conductor 1. The alternating stranding directions of the inner and outer layers create a self-locking effect, suppressing stress concentration in a single layer under tensile load, and dispersing the axial tensile force along the gradient of the stranded layer to prevent conductor breakage. The interlayer buffer layer 3 is uniformly attached to the surface of the outer stranded layer 2 through a spraying process. Its nano-ceramic particle modified elastomer undergoes elastic deformation when the cable is bent, absorbing the frictional energy between the outer stranded layer 2 and the sheath layer 4, reducing interlayer wear and blocking heat accumulation. The reinforcing braided layer 5 is embedded inside the sheath layer 4 with an asymmetrical mesh structure of dense warp and loose weft. When stretched longitudinally, the warp fibers preferentially bear the load, directionally improving the tensile strength, while the low-density weft design maintains the lateral flexibility of the sheath layer 4, allowing the cable to adapt to small-radius bends. The sheath layer 4 is integrated with the reinforcing braided layer 5 through a fusion embedding process, forming a continuous and dense interface after curing. This not only resists external mechanical impact and the intrusion of corrosive media, but also, through the synergistic effect of the reinforcing braided layer 5 and the interlayer buffer layer 3, gradually transfers external stress to the gradient stranded structure of the inner conductor 1 and the outer stranded layer 2, ultimately achieving a comprehensive improvement in tensile strength, bending life, and dynamic stability.

[0031] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, or similar improvements made within the theoretical and principle content of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A high-tensile multi-layer stranded power cable, characterized in that: It includes an inner conductor (1); an outer stranded layer (2) is sleeved on the surface of the inner conductor (1), an interlayer buffer layer (3) is sleeved on the surface of the outer stranded layer (2), an reinforcing braided layer (5) is provided on the surface of the interlayer buffer layer (3), and a sheath layer (4) is sleeved on the surface of the reinforcing braided layer (5). The inner conductor (1) is formed by stranding metal wires. The outer stranded layer (2) is formed by spirally winding metal wires around the outer surface of the inner conductor (1) and the stranding direction is opposite to that of the inner conductor (1). The interlayer buffer layer (3) covers the surface of the outer stranded layer (2). The sheath layer (4) covers the outside of the interlayer buffer layer (3).

2. The high tensile strength multilayer stranded power cable according to claim 1, characterized in that: The sheath layer (4) has an embedded reinforcing braided layer (5), which is a mesh structure with a warp braid density greater than the weft braid density and completely covers the outer surface of the interlayer buffer layer (3).

3. The high tensile strength multilayer stranded power cable according to claim 1, characterized in that: The metal wires of the outer stranded layer (2) are spirally wound in alternating directions, with the stranding directions of adjacent spiral layers being opposite.

4. A high tensile strength multilayer stranded power cable according to claim 1, characterized in that: The mesh structure of the reinforcing braided layer (5) is integrated with the sheath layer (4) through a melt-embedding process and is located entirely on the radial inner side of the sheath layer (4).

5. A high tensile strength multilayer stranded power cable according to claim 1, characterized in that: The interlayer buffer layer (3) is attached to the surface of the outer stranded layer (2) by a spraying process, and the sheath layer (4) is coated with the interlayer buffer layer (3) by a curing process to form a continuous interface with it.

6. A high tensile strength multilayer stranded power cable according to claim 1, characterized in that: The inner conductor (1) is twisted in a right-handed direction, and the outermost spiral of the outer stranded layer (2) is wound in a left-handed direction.

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