Aluminum alloy core photovoltaic cable
By using aramid fiber reinforced core and multi-layer structure design in aluminum alloy core photovoltaic cables, the problem of insufficient tensile strength of cables is solved, achieving both lightweighting and protective effects.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- JIANGSU XINCHANGFENG CABLE
- Filing Date
- 2025-06-13
- Publication Date
- 2026-05-15
AI Technical Summary
Existing aluminum alloy core photovoltaic cables are prone to breakage due to tensile stress during use, and their tensile resistance is insufficient.
The cable uses an aramid fiber reinforced core instead of a traditional steel core, and combines a braided layer, an armor layer, an inner sheath, and an outer sheath design to enhance the cable's tensile strength.
The cable's tensile strength has been improved, resulting in a lightweight design, and its multi-layered structure provides protection and cushioning to prevent damage.
Smart Images
Figure CN224248328U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of wire and cable technology, specifically to an aluminum alloy core photovoltaic cable. Background Technology
[0002] Photovoltaic cables are an indispensable component of photovoltaic (PV) power generation systems. They are primarily used to connect solar panels and solar inverters, transmitting the electricity generated by the PV system to power plants or energy storage devices. Therefore, aluminum-core PV cables have emerged. These cables are mainly used to connect PV modules, combiner boxes, inverters, and other equipment to collect, convert, and transmit solar power. Aluminum-core PV cables can also be used for power supply in transportation systems such as urban rail transit and highway lighting. With the development of new energy technologies, aluminum-core PV cables have also found widespread application in renewable energy fields such as solar and wind power.
[0003] For example, Chinese patent CN221899773U discloses an aluminum alloy core photovoltaic cable, including a steel tape armor. A rubber layer is fixedly sleeved on the outer side of the steel tape armor, and multiple octagonal elastic steel rings are fixedly sleeved inside the rubber layer. A waterproof coating is fixedly sleeved on the outer side of the rubber layer. In this invention, when the cable is being dragged and installed, the anti-wear steel bolts contact the ground, while the shade net does not, preventing damage to the cable surface. Furthermore, the shade net can block sunlight, preventing the cable from aging due to prolonged sun exposure. Additionally, when the outer side of the cable is subjected to pressure, the deformation of the rubber layer and the octagonal elastic steel rings reduces the pressure. The inward pressure from the rubber layer and the octagonal elastic steel rings presses onto the steel tape armor, which bears all the remaining pressure, ensuring that the cable core is not affected by pressure and improving the working quality of the aluminum alloy core photovoltaic cable.
[0004] However, due to the special environment in which photovoltaic cables are used, and the fact that the cables are prone to breakage due to their own weight and external pulling after installation, affecting their use, the tensile strength requirements for photovoltaic cables are becoming increasingly higher in order to ensure their quality of use while ensuring that they are not easily broken. Utility Model Content
[0005] The technical problem to be solved by this utility model is to overcome the defects of the existing technology and provide an aluminum alloy core photovoltaic cable that can effectively relieve tensile stress and greatly improve the tensile performance of the cable.
[0006] To solve the above-mentioned technical problems, the technical solution of this utility model is: an aluminum alloy core photovoltaic cable, including a core layer, the core layer including a core sheath, the core sheath having a plurality of conductors, a reinforcing core having a center in the core layer, the conductors surrounding the reinforcing core, an insulation layer and a shielding layer being sequentially provided on the outer side of the conductors, a reinforcing layer and a sheath layer being sequentially provided on the outer side of the core layer, the reinforcing layer including a braided layer and an armor layer disposed on the outer side of the core layer, and the sheath layer including an inner sheath and an outer sheath being sequentially disposed on the outer side of the reinforcing layer.
[0007] Furthermore, the conductors are filled with a filler material, which is made of polyester fibers spirally wound or placed in parallel and wrapped around the conductors.
[0008] Furthermore, the reinforcing core is an aramid fiber reinforcing core.
[0009] Furthermore, the insulating layer is made of high-performance cross-linked polyolefin.
[0010] Furthermore, the shielding layer is woven from copper wire.
[0011] Furthermore, after the conductor is stranded, two layers of non-woven fabric are wrapped around its outer side to form a non-woven fabric layer.
[0012] Furthermore, the braided layer is a layer of aramid fiber woven on the outside of the core sheath.
[0013] Furthermore, the armor layer is spirally wrapped around the woven layer with a certain overlap ratio by fine steel strips, and the fine steel strips are wrapped in two layers.
[0014] Furthermore, the inner sheath is made of a soft cross-linked polyolefin material, and the inner sheath is filled with a flame-retardant material, which is a halogen-free, low-smoke flame-retardant material.
[0015] Furthermore, the outer sheath is made of high-performance cross-linked polyolefin with a thickness ≥1.0mm.
[0016] By adopting the above technical solution, this utility model has the following beneficial effects:
[0017] 1. A reinforcing core is provided at the center of the core layer, and the conductor is arranged around the reinforcing core. The reinforcing core is an aramid fiber reinforced core with a tensile strength >2000Mpa. The aramid fiber reinforced core is used to replace the traditional steel core to reduce weight and achieve lightweight cable.
[0018] 2. The braided layer is a layer of aramid fiber woven on the outside of the core sheath. Aramid fiber has the characteristics of ultra-high strength, high modulus, low density, high temperature resistance and non-melting, which can provide the cable with excellent tensile strength.
[0019] 3. The armor layer is made of fine steel strips spirally wrapped around the woven layer with a certain overlap rate, and the fine steel strips are wrapped in two layers to improve strength;
[0020] 4. It is equipped with an inner sheath and an outer sheath. The function of the inner sheath is to protect the reinforcing layer from damage during subsequent processing or use, and to provide a certain buffering effect. The outer sheath better wraps the internal structure, shares some of the tensile stress, and protects the reinforcing layer. Attached Figure Description
[0021] Figure 1 This is a schematic diagram of the structure of the aluminum alloy core photovoltaic cable of this utility model.
[0022] Reference numerals: 1. Core layer; 2. Reinforcing layer; 3. Sheath layer; 10. Core sheath;
[0023] 11. Conductor; 12. Reinforcing core; 13. Insulating layer; 14. Shielding layer; 15. Non-woven fabric layer; 16. Filler;
[0024] 21. Braided layer; 22. Armored layer; 31. Inner sheath; 32. Outer sheath. Detailed Implementation
[0025] To make the contents of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings.
[0026] like Figure 1 As shown, in this embodiment, an aluminum alloy core photovoltaic cable is provided, including a core layer 1, a core sheath 10, a plurality of conductors 11 inside the core sheath 10, an insulation layer 13 and a shielding layer 14 sequentially disposed on the outside of the conductors 11, a reinforcing layer 2 and a sheath layer 3 sequentially disposed on the outside of the core layer 1, the reinforcing layer 2 including a braided layer 21 and an armor layer 22 disposed on the outside of the core layer 1, and the sheath layer 3 including an inner sheath 31 and an outer sheath 32 sequentially disposed on the outside of the reinforcing layer 2.
[0027] In this embodiment, conductor 11 is an AA8030 series aluminum alloy conductor.
[0028] like Figure 1 As shown, in this embodiment, after the conductor 11 is stranded, two layers of non-woven fabric are wrapped around its outer side to form a non-woven fabric layer 15. The non-woven fabric is a white, lightweight, and environmentally friendly non-woven fabric, and the wrapping overlap is greater than 15%. The conductors 11 are filled with filler 16. The filler 16 is made of polyester fiber spirally wound or placed in parallel and wrapped around the conductor. The filler 16 can fill the gaps between the strands of the conductor 11, preventing the conductor 11 from becoming loose, deformed, or having a single filament punctured by pressure when stretched. At the same time, it can transmit and disperse the tensile force more evenly.
[0029] In this embodiment, a reinforcing core 12 is provided at the center of the core sheath 10, and the conductor 11 is arranged around the reinforcing core 12. The material of the reinforcing core 12 is aramid fiber reinforced core, which has a tensile strength >2000Mpa. The aramid fiber reinforced core is used to replace the traditional steel core to reduce weight and achieve the lightweighting of the cable.
[0030] like Figure 1 As shown, in this embodiment, the insulating layer 13 is made of high-performance cross-linked polyolefin. The cross-linked structure provides excellent heat resistance, mechanical strength (including tensile strength and tear strength), and resistance to environmental stress cracking. The shielding layer 14 is woven from copper wire. The shielding layer 14 is at the same potential as the core layer 1 and maintains good contact with the insulating layer 13 to avoid partial discharge between the conductor 11 and the insulating layer 13.
[0031] In this embodiment, the braided layer 21 is a layer of aramid fiber woven on the outside of the core sheath 10. Aramid fibers have characteristics such as ultra-high strength, high modulus, low density, high temperature resistance, and non-melting, which can provide the cable with excellent tensile strength.
[0032] like Figure 1 As shown, in this embodiment, the armor layer 22 is spirally wrapped around the braided layer 21 with a certain overlap ratio by a thin steel strip, and the thin steel strip is wrapped in two layers to improve the strength.
[0033] like Figure 1 As shown, in this embodiment, the inner sheath 31 is made of a soft cross-linked polyolefin material. The function of the inner sheath 31 is to protect the reinforcing layer 2 from damage during subsequent processing or use, and to provide a certain buffering effect. Simultaneously, flame-retardant material is filled into the inner sheath 31. This flame-retardant material is a halogen-free, low-smoke flame-retardant material, which has good flame-retardant performance, low toxicity, and good smoke suppression effect. The inorganic flame-retardant material used in this solution is magnesium hydroxide. When heated, magnesium hydroxide decomposes and absorbs heat from the surface of the burning material, thus achieving a flame-retardant effect. Simultaneously, it releases a large amount of water to dilute the oxygen on the surface of the burning material. The active magnesium oxide generated by the decomposition adheres to the surface of the combustible material, further preventing combustion. Magnesium hydroxide can also reduce the amount of smoke produced when plastics burn, acting as a smoke suppressant. Magnesium hydroxide also has the advantages of being safe and non-toxic, and having good thermal stability during high-temperature processing.
[0034] like Figure 1 As shown, the outer sheath 32 is made of high-performance cross-linked polyolefin with a thickness of ≥1.0mm. The outer sheath 32 can improve the overall mechanical protection of the cable (including tensile strength, compression resistance, and abrasion resistance), better wrap the internal structure, share some of the tensile stress, and protect the reinforcing layer 2.
[0035] The beneficial effects of this utility model are as follows: A reinforcing core 12 is provided at the center of the core layer 1, and the conductor 11 is arranged around the reinforcing core 12. The reinforcing core 12 is an aramid fiber reinforced core with a tensile strength >2000Mpa. The aramid fiber reinforced core is used to replace the traditional steel core to reduce weight and achieve cable lightweighting. The braided layer 21 is a layer of aramid fiber braided on the outside of the core sheath 10. Aramid fibers have ultra-high strength, high modulus, low density, high temperature resistance, and non-melting properties, which can provide the cable with excellent tensile performance. The armor layer 22 is made of fine steel strip spirally wrapped around the braided layer 21 with a certain overlap rate, and the fine steel strip is wrapped in two layers to improve strength. At the same time, an inner sheath 31 and an outer sheath 32 are also provided. The function of the inner sheath 31 is to protect the reinforcing layer 2 from damage during subsequent processing or use, and to provide a certain buffering effect. The outer sheath 32 better wraps the internal structure, shares some of the tensile stress, and protects the reinforcing layer 2.
[0036] The specific embodiments described above further illustrate the technical problems, technical solutions, and beneficial effects of this utility model. It should be understood that the above descriptions are merely specific embodiments of this utility model and are not intended to limit this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.
Claims
1. A photovoltaic cable with an aluminum alloy core, characterized in that: The core layer (1) includes a core sheath (10), which contains a plurality of conductors (11). A reinforcing core (12) is provided at the center of the core layer (1), and the conductors (11) surround the reinforcing core (12). An insulation layer (13) and a shielding layer (14) are provided on the outside of the conductors (11). A reinforcing layer (2) and a sheath layer (3) are provided on the outside of the core layer (1). The reinforcing layer (2) includes a braided layer (21) and an armor layer (22) disposed on the outside of the core layer (1). The sheath layer (3) includes an inner sheath (31) and an outer sheath (32) disposed on the outside of the reinforcing layer (2).
2. The aluminum alloy core photovoltaic cable according to claim 1, characterized in that: The conductors (11) are filled with filler (16), which is made of polyester fibers spirally wound or placed in parallel on the conductors (11).
3. The aluminum alloy core photovoltaic cable according to claim 1, characterized in that: The reinforcing core (12) is an aramid fiber reinforcing core.
4. The aluminum alloy core photovoltaic cable according to claim 1, characterized in that: The insulating layer (13) is made of high-performance cross-linked polyolefin.
5. The aluminum alloy core photovoltaic cable according to claim 1, characterized in that: The shielding layer (14) is woven from copper wire.
6. The aluminum alloy core photovoltaic cable according to claim 1, characterized in that: After the conductor (11) is twisted, two layers of non-woven fabric are wrapped around its outer side to form a non-woven fabric layer (15).
7. The aluminum alloy core photovoltaic cable according to claim 1, characterized in that: The braided layer (21) is a layer of aramid fiber woven on the outside of the core sheath (10).
8. The aluminum alloy core photovoltaic cable according to claim 1, characterized in that: The armor layer is made of fine steel strips spirally wrapped around the braided layer (21) with a certain overlap ratio, and the fine steel strips are wrapped in two layers.
9. The aluminum alloy core photovoltaic cable according to claim 1, characterized in that: The inner sheath (31) is made of a soft cross-linked polyolefin material, and the inner sheath (31) is filled with a flame retardant material, which is a halogen-free low-smoke flame retardant material.
10. The aluminum alloy core photovoltaic cable according to claim 1, characterized in that: The outer sheath (32) is made of high-performance cross-linked polyolefin with a thickness ≥1.0mm.