Copper core overhead cable
By adopting a soft copper core conductor and a composite sheath structure, the problems of high resistance, poor bending performance and high construction difficulty of existing copper core overhead insulated conductors are solved, realizing efficient power transmission and stability of the cable, and adapting to the construction needs of humid environments.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- TBEA XINJIANG CABLE CO LTD
- Filing Date
- 2025-04-03
- Publication Date
- 2026-05-05
AI Technical Summary
Existing copper core overhead insulated conductors have high resistance, poor bending performance, high construction costs, and high construction difficulty. In addition, traditional sheath materials have low mechanical strength and poor wear resistance, making them difficult to meet the stability requirements of humid areas and densely populated urban areas.
It adopts a soft copper core conductor, water-blocking paste and composite sheath structure, including conductor wrapping layer, conductor shielding layer, insulation layer and outer sheath layer. Through multi-strand micro copper wire bundle twisting and water-blocking tape design, the conductor flexibility and waterproof performance are improved. Combined with the outer sheath layer woven with bulletproof wire and nylon wire, the cable's flexibility and wear resistance are enhanced.
It increases the current carrying capacity of the conductor, reduces resistance loss, enhances the bending flexibility and fatigue resistance of the cable, ensures the stability and service life of the cable in humid environments, and reduces construction difficulty and cost.
Smart Images
Figure CN224203879U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of cable production technology, and specifically relates to a copper core overhead cable. Background Technology
[0002] With the rapid development of the power transmission and distribution industry, the demand for power supply is constantly increasing, and the market prospects are broad. At present, copper core overhead insulated conductors are generally made of hard copper, which has problems such as high resistance, poor bending performance, high construction cost, and high construction difficulty. They are difficult to adapt to various scenarios with high stability requirements, such as humid areas, densely populated urban areas, and the connection of equipment at the end of the distribution network.
[0003] In addition, traditional polyvinyl chloride (PVC) or polyethylene (PE) sheathed cables have low mechanical strength (tensile strength < 20 MPa) and poor abrasion resistance (wear loss > 10 MPa).
[0004] The 200mm³ defect makes it susceptible to damage from external forces, leading to insulation failure. Furthermore, the conductor lacks a dedicated water-blocking layer, allowing moisture penetration and causing copper core oxidation (increasing contact resistance by more than 200 mm³).
[0005] 15%) and insulation breakdown (breakdown field strength decrease >30%). Although there are improved solutions such as metal armor or single-material reinforced sheaths, these result in increased cable weight (20% to 15%).
[0006] Problems such as insufficient strength under dynamic stress (40%) severely restrict the construction and installation of power transmission and distribution lines in special environments. Utility Model Content
[0007] The technical problem to be solved by this utility model is to provide a copper core overhead cable that addresses the above-mentioned shortcomings of the existing technology. This cable has the properties of good flexibility and low resistance, and solves the problems of poor bending performance, high conductor loss, high construction cost and high construction difficulty that exist in the use of conventional overhead insulated cables.
[0008] The technical solution of this utility model to solve the above-mentioned technical problems is:
[0009] This utility model provides a copper core overhead cable, which includes a soft copper core conductor, a conductor wrapping layer, a conductor shielding layer, an insulation layer, and an outer sheath layer. The conductor wrapping layer, the conductor shielding layer, the insulation layer, and the outer sheath layer are sequentially wrapped around the soft copper core conductor from the inside to the outside. The soft copper core conductor includes several strands of wire, which are twisted together. Each strand includes several soft copper single wires, which are bundled together. The gaps between the strands are filled with water-blocking paste.
[0010] Optionally, the soft copper single wire is a soft copper conductor with a diameter of 0.15 to 0.5 mm of fine single wire.
[0011] Optionally, the twisted diameter ratio of the soft copper single wire is 15 to 25 times, and the twisted diameter ratio of the strand wire is 10 to 12 times.
[0012] Optionally, the stranding direction of the soft copper single wire is the same as the twisting direction of the strand wire, for example, both are left-handed or right-handed.
[0013] Optionally, the conductor wrapping layer is a water-blocking tape, which has a single-layer overlapping wrapping structure, and the wrapping direction is opposite to the stranding direction of the soft copper core conductor, with an overlap rate of 30% to 50%.
[0014] Optionally, the water-blocking strip is made of metal composite material.
[0015] Optionally, the conductor shielding layer is formed by extruding a semi-conductive shielding material.
[0016] Optionally, the insulating layer is made of cross-linked polyethylene through extrusion, which forms a composite layer structure with the water-blocking tape and the conductor shielding layer.
[0017] Optionally, the outer sheath layer is composed of cross-woven bulletproof wire and nylon wire, and the weaving method is a three-dimensional forward weaving method, wherein the bulletproof wire is spirally wound along the Z-axis, and the nylon wire is orthogonally woven in the XY plane.
[0018] Optionally, the braiding cross angle of the outer sheath layer is 60° to 90°, and the braiding density is 20 to 50 strands / 10cm2.
[0019] The copper core overhead cable of this utility model has the following beneficial effects:
[0020] (1) The soft copper core conductor is used. Compared with the hard copper core conductor, the soft copper core conductor is formed by twisting multiple strands of fine copper wires. The contact area is significantly larger than that of a single strand of hard copper core conductor. The resistance is small. According to the skin effect principle, the alternating current is more concentrated on the conductor surface for transmission. Therefore, the effective current carrying area of the soft copper core conductor is larger, and its current carrying capacity is about 10% to 15% higher than that of the hard copper core conductor. This reduces resistance loss and improves power transmission efficiency.
[0021] (2) The soft copper core conductor adopts a multi-strand stranded structure design, which is formed by stranding multiple fine copper wires together. The strands are twisted in the same direction, and the bending radius can reach 1 / 2 of that of ordinary overhead cables. The cable is more flexible and can adapt to narrow spaces or multi-turn areas. Flexible wiring can be achieved without additional auxiliary tools, reducing construction difficulty and labor costs.
[0022] (3) Compared with hard copper core conductors, which are usually produced by frame stranding machines, the residual stress inside cannot be offset because the stranding process does not untwist. During long-term use, the conductor is prone to line faults caused by fatigue fracture. Soft copper core conductors are produced by cage stranding machines, and the stranding process of the single wires is untwist. There is basically no residual stress inside, and the fatigue fracture resistance and tensile strength performance can be improved by about 10%.
[0023] (4) By setting water-blocking tape and / or water-blocking paste, the cable has excellent water-blocking performance, which can prevent rainwater from penetrating longitudinally and avoid the problem of conductor oxidation, corrosion and breakage. It effectively ensures the safety and reliability of the cable during transportation and better meets the needs of the market. At the same time, compared with the improved scheme of metal armor or single material reinforced sheath, the cable also has the properties of low self-weight.
[0024] (5) The outer sheath layer is made of bulletproof wire and nylon wire arranged alternately in the warp and weft directions, which can simultaneously take into account the flexibility, wear resistance, weather resistance, high temperature resistance, UV resistance, acid and alkali resistance, high tensile strength and aging resistance of the cable sheath, adapt to the dynamic stress environment of overhead cables and improve service life. Attached Figure Description
[0025] Figure 1 This is a schematic diagram of the structure of the copper core overhead cable in the embodiment of this utility model.
[0026] In the diagram: 1-Soft copper core conductor; 2-Water-blocking paste; 3-Conductor wrapping layer; 4-Conductor shield; 5-Insulation layer; 6-Outer sheath layer. Detailed Implementation
[0027] To enable those skilled in the art to better understand the technical solution of this utility model, the technical solution of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.
[0028] To address the problems of poor bending performance, high conductor loss, high construction cost, and high construction difficulty in existing copper-core overhead insulated conductors, this utility model discloses a copper-core overhead cable, which includes a soft copper core conductor, a conductor wrapping layer, a conductor shielding layer, an insulation layer, and an outer sheath layer. The conductor wrapping layer, the conductor shielding layer, the insulation layer, and the outer sheath layer are sequentially wrapped around the soft copper core conductor from the inside out. The soft copper core conductor includes several strands of wire, which are twisted together. Each strand includes several soft copper single wires, which are bundled together. The gaps between the strands are filled with water-blocking paste.
[0029] Example 1
[0030] like Figure 1 As shown, this embodiment discloses a copper core overhead cable, which includes a soft copper core conductor 1, a conductor wrapping layer 3, a conductor shielding layer 4, an insulation layer 5, and an outer sheath layer 6. The conductor wrapping layer 3, the conductor shielding layer 4, the insulation layer 5, and the outer sheath layer 6 are wrapped around the soft copper core conductor 1 from the inside out. In other words, the cable consists of a soft copper core conductor 1, a conductor wrapping layer 3, a conductor shielding layer 4, an insulation layer 5, and an outer sheath layer 6 from the inside out. The soft copper core conductor 1 adopts the fifth type of soft copper conductor specified in GB / T 3956 "Conductors of Cables".
[0031] Specifically, the soft copper core conductor 1 comprises several strands of wire, which are twisted together. Each strand includes several soft copper single wires, which are twisted together. Furthermore, after the soft copper core conductor 1 is twisted, the gaps between the strands are filled with water-resistant paste 2.
[0032] In some embodiments, the soft copper single wire is a soft copper conductor with a diameter of 0.15 to 0.5 mm (i.e., a fine copper wire). That is to say, the soft copper core conductor is formed by first bundling and then re-twisting several soft copper conductors with a diameter of 0.15 to 0.50 mm.
[0033] In some implementations, the twisted diameter ratio of the soft copper single wire is 15 to 25 times, and the twisted diameter ratio of the strand wire is 10 to 12 times.
[0034] In some embodiments, the cross-sectional area of the soft copper core conductor 1 is 6–120 mm². 2 .
[0035] In some embodiments, the stranding direction of the soft copper single wire is the same as the re-stretching direction of the strands, both being left-handed or right-handed. This results in a large relative slip distance between the soft copper core conductor layers, good flexibility, and facilitates laying in narrow spaces and areas with multiple corners, thereby reducing construction costs and difficulty.
[0036] In some embodiments, the conductor wrapping layer 3 is a water-blocking tape, which has a single-layer overlapping wrapping structure and the wrapping direction is opposite to the twisting direction of the soft copper core conductor 1, with an overlap rate of 30% to 50%, thereby offsetting the stress generated when the cable is bent and laid, and reducing the risk of water-blocking tape breakage.
[0037] In some embodiments, the water-blocking tape is made of metal composite material to prevent moisture from penetrating longitudinally along the conductor, avoid insulation layer breakdown due to moisture, and improve the stability of cable operation.
[0038] In some embodiments, the nominal thickness of the water-blocking strip is 0.04 to 0.06 mm.
[0039] In some embodiments, the conductor shielding layer 4 is made of a semi-conductive shielding material through extrusion to achieve uniform electric field distribution and reduce partial discharge.
[0040] In some embodiments, the thickness of the conductor shielding layer 4 is 0.7 to 0.9 mm.
[0041] In some embodiments, the insulation layer 5 is made of cross-linked polyethylene (XLPE) extruded. It can be combined with the water-blocking tape and the conductor shielding layer 4 to form a composite layer structure of water-blocking tape + semi-conductive tape + insulation layer inside the cable. This composite layer structure can achieve triple protection of "moisture-proof-shielding-insulation", which can ensure the performance of the cable during long-term high-temperature operation and avoid problems such as cable insulation aging and decreased insulation resistance.
[0042] In some embodiments, the nominal thickness of the insulation layer 5 is 1.8 to 3.4 mm, and for 10kV and above cables, the thickness of the insulation layer is preferably 3.4 mm.
[0043] In some embodiments, the outer sheath layer 6 is composed of cross-woven bulletproof wire and nylon wire. Compared with the black polyvinyl chloride used in traditional technology, the bulletproof wire and nylon wire have better UV resistance and acid and alkali resistance. The weaving method is a three-dimensional forward weaving method, in which the bulletproof wire is spirally wound along the Z-axis and the nylon wire is orthogonally woven in the XY plane. This can take into account the advantages of cable flexibility and tensile strength.
[0044] In some embodiments, the outer sheath layer 6 has a braided thickness of 0.5 to 1.0 mm.
[0045] In some embodiments, the braiding cross angle of the outer sheath layer 6 is 60° to 90°, and the braiding density is 20 to 50 strands / 10cm2. This allows the tensile strength of the bulletproof wire (such as aramid fiber) to reach 3 to 4 GPa, which is more than 4 times the strength of steel wire. This ensures that the mechanical stress requirements of overhead laying conditions are met. At the same time, the nylon wire can provide cushioning and surface protection. In addition, the high temperature resistance of the bulletproof wire can not only compensate for the performance degradation of nylon at high temperatures, but also ensure that the high tensile strength, impact resistance, vibration fatigue resistance and weather resistance of the cable are met in special environments. This is of great benefit to improving the overall performance of overhead cables.
[0046] The copper core overhead cable of this embodiment has the following advantages:
[0047] (1) The soft copper core conductor is used. Compared with the hard copper core conductor, the soft copper core conductor is formed by twisting multiple strands of fine copper wires. The contact area is significantly larger than that of a single strand of hard copper core conductor. The resistance is small. According to the skin effect principle, the alternating current is more concentrated on the conductor surface for transmission. Therefore, the effective current carrying area of the soft copper core conductor is larger, and its current carrying capacity is about 10% to 15% higher than that of the hard copper core conductor. This reduces resistance loss and improves power transmission efficiency.
[0048] (2) The soft copper core conductor adopts a multi-strand stranded structure design, which is formed by stranding multiple fine copper wires together. The strands are twisted in the same direction, and the bending radius can reach 1 / 2 of that of ordinary overhead cables. The cable is more flexible and can adapt to narrow spaces or multi-turn areas. Flexible wiring can be achieved without additional auxiliary tools, reducing construction difficulty and labor costs.
[0049] (3) Compared with hard copper core conductors, which are usually produced by frame stranding machines, the residual stress inside cannot be offset because the stranding process does not untwist. During long-term use, the conductor is prone to line faults caused by fatigue fracture. Soft copper core conductors are produced by cage stranding machines, and the stranding process of the single wires is untwist. There is basically no residual stress inside, and the fatigue fracture resistance and tensile strength performance can be improved by about 10%.
[0050] (4) By setting water-blocking tape and / or water-blocking paste, the cable has excellent water-blocking performance, which can prevent rainwater from penetrating longitudinally and avoid the problem of conductor oxidation, corrosion and breakage. It effectively ensures the safety and reliability of the cable during transportation and better meets the needs of the market. At the same time, compared with the improved scheme of metal armor or single material reinforced sheath, the cable also has the properties of low self-weight.
[0051] (5) The outer sheath layer is made of bulletproof wire and nylon wire arranged alternately in the warp and weft directions, which can simultaneously take into account the flexibility, wear resistance, weather resistance, high temperature resistance, UV resistance, acid and alkali resistance, high tensile strength and aging resistance of the cable sheath, adapt to the dynamic stress environment of overhead cables and improve service life.
[0052] Example 2
[0053] This embodiment discloses a copper core overhead cable, which differs from Embodiment 1 in that:
[0054] In this embodiment, the cross-sectional area of the soft copper core conductor 1 is 35 mm². 2 The soft copper core conductor 1 is made of 30 strands of 0.4mm TR type or TR1 type soft copper single wire bundles twisted together, and then 10 strands are re-twisted in a 2+8 arrangement.
[0055] In this embodiment, the twisted section diameter ratio of the soft copper single wire is 22 times, and the twisted section diameter ratio of the strand wire is 10.5 times.
[0056] In this embodiment, the stranding direction of the soft copper single wire and the re-stretching direction of the strand are both to the left.
[0057] In this embodiment, the water-blocking tape has a wrapping overlap rate of 30%, a wrapping direction of right-hand, and a nominal thickness of 0.04 mm.
[0058] In this embodiment, the thickness of the conductor shielding layer 4 is 0.7 mm.
[0059] In this embodiment, the nominal thickness of the insulating layer 5 is 3.4 mm.
[0060] In this embodiment, the outer sheath layer 6 has a braiding thickness of 0.5 mm.
[0061] In this embodiment, the cross angle of the outer sheath layer 6 is 60°, and the weaving density is 20 strands / 10cm2.
[0062] Example 3
[0063] This embodiment discloses a copper core overhead cable, which differs from Embodiment 1 in that:
[0064] In this embodiment, the cross-sectional area of the soft copper core conductor 1 is 70 mm². 2 The soft copper core conductor 1 is made of 28 strands of 0.5mm TR type or TR1 type soft copper single wire bundles twisted together, and then 13 strands are re-twisted in a 1+3+9 arrangement.
[0065] In this embodiment, the twisted section diameter ratio of the soft copper single wire is 24 times, and the twisted section diameter ratio of the strand wire is 11 times.
[0066] In this embodiment, the stranding direction of the soft copper single wire and the re-stretching direction of the strand are both to the left.
[0067] In this embodiment, the water-blocking tape has a wrapping overlap rate of 50%, a wrapping direction of right, and a nominal thickness of 0.05 mm.
[0068] In this embodiment, the thickness of the conductor shielding layer 4 is 0.8 mm.
[0069] In this embodiment, the nominal thickness of the insulating layer 5 is 3.4 mm.
[0070] In this embodiment, the outer sheath layer 6 has a braiding thickness of 0.5 mm.
[0071] In this embodiment, the braided cross angle of the outer sheath layer 6 is within the range of 65°±1°, and the braiding density is 25 strands / 10cm2.
[0072] Example 4
[0073] This embodiment discloses a copper core overhead cable, which differs from Embodiment 1 in that:
[0074] In this embodiment, the cross-sectional area of the soft copper core conductor 1 is 120 mm². 2 The soft copper core conductor 1 is made of 29 strands of 0.45mm TR type or TR1 type soft copper single wire bundles twisted together, and then 19 strands are re-twisted in a 1+6+12 arrangement.
[0075] In this embodiment, the twisted section diameter ratio of the soft copper single wire is 20.5 times, and the twisted section diameter ratio of the strand wire is 11.5 times.
[0076] In this embodiment, the stranding direction of the soft copper single wire and the re-stretching direction of the strand are both to the left.
[0077] In this embodiment, the water-blocking tape has a wrapping overlap rate of 45%, a wrapping direction of right-hand, and a nominal thickness of 0.06 mm.
[0078] In this embodiment, the thickness of the conductor shielding layer 4 is 0.85 mm.
[0079] In this embodiment, the nominal thickness of the insulating layer 5 is 3.4 mm.
[0080] In this embodiment, the outer sheath layer 6 has a braided thickness of 0.8 mm.
[0081] In this embodiment, the cross angle of the outer sheath layer 6 is within the range of 80°±1°, and the weaving density is 25 strands / 10cm2.
[0082] Example 5
[0083] This embodiment discloses a copper core overhead cable, which differs from Embodiment 1 in that:
[0084] In this embodiment, the cross-sectional area of the soft copper core conductor 1 is 6 mm². 2 The soft copper core conductor is made of 30 strands of 0.15mm TR type or TR1 type soft copper single wire bundles twisted together, and then 10 strands are re-twisted in a 2+8 arrangement.
[0085] In this embodiment, the twisted section diameter ratio of the soft copper single wire is 15 times, and the twisted section diameter ratio of the strand wire is 10 times.
[0086] In this embodiment, the stranding direction of the soft copper single wire and the re-stretching direction of the strand are both to the left.
[0087] In this embodiment, the water-blocking tape has a wrapping overlap rate of 35%, a wrapping direction of right-hand, and a nominal thickness of 0.045 mm.
[0088] In this embodiment, the thickness of the conductor shielding layer 4 is 0.75 mm.
[0089] In this embodiment, the nominal thickness of the insulating layer 5 is 3.4 mm.
[0090] In this embodiment, the outer sheath layer 6 has a braided thickness of 0.6 mm.
[0091] In this embodiment, the cross angle of the outer sheath layer 6 is 70°, and the weaving density is 50 strands / 10cm2.
[0092] Example 6
[0093] This embodiment discloses a copper core overhead cable, which differs from Embodiment 1 in that:
[0094] In this embodiment, the cross-sectional area of the soft copper core conductor 1 is 25 mm². 2 The soft copper core conductor 1 is made of 30 strands of 0.3mm TR type or TR1 type soft copper single wire bundles twisted together, and then 10 strands are re-twisted in a 2+8 arrangement.
[0095] In this embodiment, the twisted section diameter ratio of the soft copper single wire is 25 times, and the twisted section diameter ratio of the strand wire is 12 times.
[0096] In this embodiment, the stranding direction of the soft copper single wire and the re-stretching direction of the strand are both to the left.
[0097] In this embodiment, the water-blocking tape has a wrapping overlap rate of 40%, a wrapping direction of right-hand, and a nominal thickness of 0.055mm.
[0098] In this embodiment, the thickness of the conductor shielding layer 4 is 0.9 mm.
[0099] In this embodiment, the nominal thickness of the insulating layer 5 is 3.4 mm.
[0100] In this embodiment, the outer sheath layer 6 has a braided thickness of 1.0 mm.
[0101] In this embodiment, the cross angle of the outer sheath layer 6 is 90°, and the weaving density is 40 strands / 10cm2.
[0102] It is understood that the above embodiments are merely exemplary implementations used to illustrate the principles of this utility model, and the utility model is not limited thereto. For those skilled in the art, various modifications and improvements can be made without departing from the spirit and essence of this utility model, and these modifications and improvements are also considered to be within the protection scope of this utility model.
Claims
1. A copper core overhead cable, characterized in that, It includes a soft copper core conductor, a conductor wrapping layer, a conductor shielding layer, an insulation layer, and an outer sheath layer. The conductor wrapping layer, the conductor shielding layer, the insulation layer, and the outer sheath layer are sequentially wrapped around the soft copper core conductor from the inside out; The soft copper core conductor includes several strands of wire, which are twisted together. Each strand includes several soft copper single wires, which are twisted together. The gaps between the strands are filled with water-blocking paste. The stranding direction of the soft copper single wire is the same as the re-stretching direction of the strand wire. The conductor wrapping layer is a water-blocking tape. The conductor shielding layer is made of semi-conductive shielding material extruded. The insulation layer is made of cross-linked polyethylene extruded and forms a composite layer structure of "moisture-proof-shielding-insulation" triple protection with the water-blocking tape and the conductor shielding layer. The outer sheath layer is composed of cross-woven bulletproof wire and nylon wire.
2. The copper core overhead cable according to claim 1, characterized in that, The soft copper single wire is a soft copper conductor with a diameter of 0.15~0.5mm.
3. The copper core overhead cable according to claim 1, characterized in that, The twisted section diameter ratio of the soft copper single wire is 15 to 25 times, and the twisted section diameter ratio of the strand wire is 10 to 12 times.
4. The copper core overhead cable according to claim 1, characterized in that, The conductor wrapping layer is a water-blocking tape, which has a single-layer overlapping wrapping structure, and the wrapping direction is opposite to the stranding direction of the soft copper core conductor, with an overlap rate of 30% to 50%.
5. The copper core overhead cable according to any one of claims 1-4, characterized in that, The water-blocking strip is made of metal composite material.
6. The copper core overhead cable according to claim 5, characterized in that, The outer sheath is woven in a three-dimensional forward weaving method, in which the bulletproof wire is spirally wound along the Z-axis, and the nylon wire is orthogonally woven in the XY plane.
7. The copper core overhead cable according to claim 6, characterized in that, The outer sheath layer has a weave cross angle of 60° to 90° and a weave density of 20 to 50 threads / 10cm. 2 .