Conversion monofilament for copper-aluminum flexible transition submarine cable
By using a cross-shaped interlocking design and metallurgical integration of the embedded blocks, the problem of low connection strength in the welding area between aluminum and copper wires is solved, achieving high mechanical strength and stability in the flexible copper-aluminum transition submarine cable, which is suitable for complex cabling scenarios.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- CHANGFEI (JIANGSU) OCEAN TECHNOLOGY CO LTD
- Filing Date
- 2025-04-18
- Publication Date
- 2026-05-08
AI Technical Summary
In existing technologies, the connection strength of the aluminum wire and copper wire solder joint area is low, which leads to production difficulties and poor performance.
It adopts a cross-interlocking design, which increases the contact area through the copper-aluminum interface and forms radial limit. Combined with the embedded block, it achieves metallurgical bonding, forming a seamless connection and enhancing mechanical strength and electrical performance.
It improves the mechanical connection strength of the copper-aluminum interface, reduces the risk of solder joint breakage, enhances the overall mechanical strength and flexibility of the monofilament, ensures the extrusion stability of the cable insulation layer, and is suitable for complex wiring scenarios.
Smart Images
Figure CN224217254U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of power transmission technology, specifically relating to a conversion monofilament for a copper-aluminum flexible transition submarine cable. Background Technology
[0002] Traditional submarine cable conductors widely use pure copper, primarily due to its excellent conductivity and corrosion resistance. However, copper resources are limited in the Earth's crust, and mining costs are high. Driven by environmental protection and cost reduction requirements, the industry is actively exploring solutions to replace copper with aluminum.
[0003] While aluminum conductors offer advantages such as lightweight, low cost, and abundant reserves, their resistivity is significantly higher than that of copper, and direct replacement would lead to increased cable transmission losses. Therefore, to balance electrical performance and cost, existing technologies employ a copper-aluminum transition structure: aluminum and copper wires of equal diameter are directly butt-welded using a cold welding process to maintain the consistency of conductor outer diameter and the stability of insulation extrusion.
[0004] However, the above structure has the problem of low connection strength in the weld area, which easily leads to wire breakage during production, making it inconvenient to manufacture and resulting in poor performance. Utility Model Content
[0005] The purpose of this invention is to provide a conversion monofilament for copper-aluminum flexible transition submarine cables, which solves the technical problem of low connection strength in the welding area between aluminum and copper wires in the prior art.
[0006] This utility model discloses a conversion monofilament for a copper-aluminum flexible transition submarine cable, comprising:
[0007] The four embedded blocks are made of aluminum alloy and have a melting point lower than that of pure copper and pure aluminum.
[0008] Two conductive segments, a copper wire segment and an aluminum wire segment, are provided. The connecting end of the conductive segments has a strip block. The end face of the strip block is provided with a rectangular groove. The rectangular groove extends through the width direction of the strip block to both sides of the strip block.
[0009] The two conductive segments are joined in a cross shape at their ends, forming four embedded slots. The embedded blocks are placed in the embedded slots one by one, making the monofilament have a cylindrical structure.
[0010] This application features a cross-shaped interlocking design, which increases the copper-aluminum contact area and creates radial limiting, thereby improving the mechanical connection strength of the copper-aluminum interface, dispersing stress concentration, reducing the risk of solder joint breakage, and effectively reducing the current density at the contact interface, thus reducing local resistance and improving electrical performance. The embedded block is also fused into the embedded groove, achieving metallurgical bonding, and can become an integral part of the copper and aluminum wire segments, forming a "seamless connection". This ensures a strong connection, significantly enhances the overall mechanical strength of the monofilament, and maintains the monofilament's cylindrical structure, ensuring the stability of the cable insulation extrusion and improving flexibility. This makes the stress distribution of the monofilament more uniform when bent or twisted, making it suitable for complex wiring scenarios.
[0011] Based on the above technical solution, the solution of this application can be further improved as follows:
[0012] Preferably, the width of the rectangular groove is consistent with the width of the strip block; by adopting this solution, the conductivity, mechanical stability and process feasibility are significantly improved through multiple mechanisms such as structural matching, mechanical strengthening and contact optimization.
[0013] Preferably, the conductive segment, the strip block, and the rectangular groove are arranged concentrically; this scheme ensures the overall structural symmetry, avoids stress concentration or deformation caused by eccentricity, and makes the materials in each layer subjected to uniform stress, significantly improving flexibility and fatigue resistance.
[0014] Preferably, the depth of the rectangular groove is half the thickness of the strip block. This solution maximizes the contact area between the embedded block, the conductive segment, and the strip block, thereby reducing the current density per unit area, reducing contact resistance, improving the mechanical connection strength of the copper-aluminum interface, dispersing stress concentration, and reducing the risk of solder joint breakage.
[0015] Preferably, the two sides of the strip block along its length are arc surfaces, and the arc surfaces are arranged in the same circle as the conductive segment. By adopting this solution, a continuous curvature transition is formed at the connection between the strip block and the conductive segment, which reduces stress concentration, reduces the risk of fatigue fracture, ensures uniform current distribution, reduces the risk of local overheating, enhances the structural integrity of the monofilament, and improves tensile strength.
[0016] Preferably, the width of the strip block is consistent with the radius of the monofilament; this solution ensures the connection strength between the strip block and the conductive segment and improves the connection firmness.
[0017] Preferably, the embedded block is an aluminum-silicon alloy component and is melted and placed in the embedded groove; this solution balances conductivity and process temperature, and can meet the core requirements of copper-aluminum transition connection for low melting point, high conductivity and strong interface bonding.
[0018] Through the above technical solution, this utility model achieves the following beneficial effects:
[0019] 1. This application uses strip blocks and rectangular grooves to form a cross-shaped interlocking design, which increases the contact area between copper and aluminum and forms radial limiting. This can improve the mechanical connection strength of the copper-aluminum interface, disperse stress concentration, reduce the risk of solder joint fracture, and effectively reduce the current density at the contact interface, thereby reducing local resistance and improving electrical performance.
[0020] 2. This application achieves metallurgical bonding by fusing the embedded block into the embedded groove, which can become an integral part of the copper wire segment and the aluminum wire segment, forming a "seamless connection". This ensures a strong connection, significantly enhances the overall mechanical strength of the monofilament, maintains the cylindrical structure of the monofilament, ensures the stability of the cable insulation extrusion, and improves flexibility. It also makes the stress distribution of the monofilament more uniform when it is bent or twisted, making it suitable for complex wiring scenarios. Attached Figure Description
[0021] 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. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0022] Figure 1 This is a schematic diagram of the structure of the conversion monofilament for the copper-aluminum flexible transition submarine cable described in the embodiments of this application;
[0023] Figure 2 for Figure 1 The diagram shows a groove embedded in the conversion monofilament of a copper-aluminum flexible transition submarine cable.
[0024] Figure 3 for Figure 1 The diagram shows the structure of the conductive section in the transition monofilament used in a copper-aluminum flexible transition submarine cable.
[0025] Figure 4 for Figure 3 A schematic diagram of the structure of the conductive segment connection end is shown;
[0026] Figure 5 for Figure 1 The diagram shows the state of the conversion monofilament used in the processing of the copper-aluminum flexible transition submarine cable.
[0027] Explanation of reference numerals in the attached figures:
[0028] 1. Embedded block; 2. Conductive segment; 21. Copper wire segment; 22. Aluminum wire segment; 201. Strip block; 2011. Rectangular groove; 2012. Arc surface; 3. Embedded groove. Detailed Implementation
[0029] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings. These embodiments are merely illustrative of the present invention and should not be construed as limiting the scope of protection of the present invention.
[0030] First, it should be noted that some directional terms used in the following description to clearly illustrate the technical solution of this utility model, such as the terms "upper," "lower," "front," "back," "vertical," "horizontal," "top," "bottom," "inner," and "outer," are all derived from the normal orientation of components in the conversion monofilament of the copper-aluminum flexible transition submarine cable. 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 component 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.
[0031] In this application, unless otherwise expressly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.
[0032] To better understand the above technical solutions, the following will provide a detailed description of the technical solutions in conjunction with the accompanying drawings and specific embodiments.
[0033] Example:
[0034] like Figures 1-4 As shown in the embodiment of this application, a conversion monofilament for a copper-aluminum flexible transition submarine cable is disclosed, the specific structure of which includes: four embedded blocks 1 and two conductive segments 2.
[0035] The four embedded blocks 1 are made of aluminum alloy, and their melting point is lower than that of pure copper and pure aluminum;
[0036] The two conductive segments 2 are copper wire segment 21 and aluminum wire segment 22, respectively. The connecting end of the conductive segment 2 has a strip block 201. The end face of the strip block 201 is provided with a rectangular groove 2011. The rectangular groove 2011 extends through the width direction of the strip block 201 to both sides of the strip block 201.
[0037] Among them, the two conductive segments 2 are connected in a cross shape and form four embedded grooves 3. The embedded blocks 1 are placed in the embedded grooves 3 one by one, so that the monofilament as a whole has a cylindrical structure.
[0038] For example, such as Figure 5 As shown, this application provides a processing method for a conversion monofilament for a copper-aluminum flexible transition submarine cable. Specifically, before the copper wire segment 21 and the aluminum wire segment 22 are joined, an aluminum alloy sleeve is first fitted onto a conductive segment 2. After joining, the aluminum alloy sleeve is moved to the joining area. Then, the aluminum alloy sleeve is melted and filled into the rectangular groove 2011 by heating. Finally, the processing is completed by cooling and polishing.
[0039] This utility model forms a cross-shaped interlocking design through the strip block 201 and the rectangular groove 2011, which increases the contact area between copper and aluminum and forms a radial limit. This can improve the mechanical connection strength of the copper-aluminum interface, disperse stress concentration, reduce the risk of solder joint breakage, and effectively reduce the current density at the contact interface, thereby reducing local resistance and improving electrical performance.
[0040] This invention integrates the embedded block 1 into the embedded groove 3 through fusion to achieve metallurgical bonding. It can become an integral part of the copper wire segment 21 and the aluminum wire segment 22, forming a "seamless connection". This ensures a strong connection, significantly enhances the overall mechanical strength of the monofilament, maintains the cylindrical structure of the monofilament, ensures the stability of the cable insulation extrusion, and improves flexibility. It also makes the stress distribution of the monofilament more uniform when it is bent or twisted, making it suitable for complex wiring scenarios.
[0041] In some embodiments, such as Figure 4 As shown, the width of the rectangular groove 2011 is consistent with the width of the strip block 201.
[0042] Specifically, it ensures that the strip block 201 can completely fit the groove wall when inserted into the rectangular groove 2011, thereby forming a tight mechanical fit. Its gapless connection avoids increased contact resistance or decreased mechanical stability caused by loosening, thus improving the overall performance of the monofilament.
[0043] Specifically, after the strip block 201 is fully embedded in the rectangular groove 2011, its side surface is in full contact with the groove wall, thereby significantly increasing the contact area between copper and aluminum. This reduces the resistance to current flow, lowers the contact resistance, and improves the conductivity.
[0044] Specifically, it enhances the shear strength at the joint, prevents relative sliding under bending, torsion or external force, and ensures that stress is evenly distributed between the strip blocks 201, thereby reducing local stress concentration and lowering the risk of fracture.
[0045] In summary, the above design significantly improves conductivity, mechanical stability, and process feasibility through multiple mechanisms such as structural matching, mechanical reinforcement, and contact optimization.
[0046] In some embodiments, such as Figure 4As shown, the conductive segment 2, the strip block 201 and the rectangular groove 2011 are concentrically arranged, which ensures the overall structure is symmetrical, avoids stress concentration or deformation caused by eccentricity, and makes the materials of each layer uniformly stressed, significantly improving flexibility and fatigue resistance.
[0047] In some embodiments, such as Figure 3 As shown, the depth of the rectangular groove 2011 is half the thickness of the strip block 201; this maximizes the contact area between the embedded block 1, the conductive segment 2 and the strip block 201, thereby reducing the current density per unit area, thus reducing the contact resistance, improving the mechanical connection strength of the copper-aluminum interface, dispersing stress concentration, and reducing the risk of solder joint breakage.
[0048] In some embodiments, such as Figure 3 As shown, the two sides of the strip block 201 along its length are arc surfaces 2012, and the arc surfaces 2012 are arranged in the same circle as the conductive segment 2.
[0049] The design of the arc surface 2012 creates a continuous curvature transition at the connection between the strip block 201 and the conductive segment 2, which reduces stress concentration, reduces the risk of fatigue fracture, ensures uniform current distribution, reduces the risk of local overheating, enhances the structural integrity of the monofilament, and improves tensile strength.
[0050] In some embodiments, such as Figure 3 As shown, the width of the strip block 201 is consistent with the radius of the monofilament, which ensures the connection strength between the strip block 201 and the conductive segment 2 and improves the connection firmness.
[0051] In some embodiments, the embedded block 1 is an aluminum-silicon alloy component and is melted and disposed in the embedded groove 3.
[0052] Specifically, the aluminum-silicon alloy is preferably 4043 aluminum alloy (Al-5%Si), with a melting point of 577-613℃ (eutectic point 577℃), which is 47-83℃ lower than pure aluminum (660℃) and 472-508℃ lower than copper (1085℃). Its electrical conductivity is about 82-90% of that of pure aluminum. It has the advantages of good compatibility with the copper / aluminum interface, excellent fluidity, and strong resistance to hot cracking.
[0053] By setting the embedded block 1 to be an aluminum-silicon alloy component, the conductivity and process temperature are balanced, which can meet the core requirements of copper-aluminum transition connection for low melting point, high conductivity and strong interface bonding.
[0054] Numerous specific details are set forth in this specification. However, it will be understood that embodiments of this invention may be practiced without these specific details. In some instances, well-known methods, structures, and techniques have not been shown in detail so as not to obscure the understanding of this specification.
[0055] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.
[0056] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although the utility model 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 or all of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model, and they should all be covered within the scope of the claims and specification of this utility model.
Claims
1. A conversion monofilament for a copper-aluminum flexible transition submarine cable, characterized in that, include: The four embedded blocks are made of aluminum alloy and have a melting point lower than that of pure copper and pure aluminum. Two conductive segments, a copper wire segment and an aluminum wire segment, are provided. The connecting end of the conductive segments has a strip block. The end face of the strip block is provided with a rectangular groove. The rectangular groove extends through the width direction of the strip block to both sides of the strip block. The two conductive segments are joined in a cross shape at their ends, forming four embedded slots. The embedded blocks are placed in the embedded slots one by one, making the monofilament have a cylindrical structure.
2. The conversion monofilament for copper-aluminum flexible transition submarine cable according to claim 1, characterized in that, The width of the rectangular groove is the same as the width of the strip block.
3. The conversion monofilament for copper-aluminum flexible transition submarine cable according to claim 1, characterized in that, The conductive segment, the strip block, and the rectangular groove are arranged concentrically.
4. The conversion monofilament for copper-aluminum flexible transition submarine cable according to claim 1, characterized in that, The depth of the rectangular groove is half the thickness of the strip block.
5. The conversion monofilament for copper-aluminum flexible transition submarine cable according to claim 1, characterized in that, The two sides of the strip block along its length are arc surfaces, and the arc surfaces are arranged in a circle with the conductive segment.
6. The conversion monofilament for copper-aluminum flexible transition submarine cable according to claim 1, characterized in that, The width of the strip block is the same as the radius of the monofilament.
7. The conversion monofilament for copper-aluminum flexible transition submarine cable according to claim 1, characterized in that, The embedded block is an aluminum-silicon alloy component and is melted and placed in the embedded groove.