High-speed rail transit high-temperature-resistant anti-interference power cable
By using a design that fills the conductor gap with thermally conductive gel, a double-layer composite insulation layer, a composite shielding layer, and a multi-layer sheath, the mechanical stress, heat dissipation, and electromagnetic interference problems of traditional rail vehicle power cables during high-speed operation are solved, achieving efficient heat dissipation and electromagnetic compatibility, and improving the mechanical reliability and weather resistance of the cable.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- GUANGZHOU NANYANG CABLE
- Filing Date
- 2025-03-27
- Publication Date
- 2026-05-29
AI Technical Summary
Traditional rail vehicle power cables suffer from mechanical stress, weak heat dissipation, electromagnetic interference, and insufficient weather resistance during high-speed operation, making it difficult to meet the lightweight and high reliability requirements of high-speed rail transit.
The design employs a combination of conductor gap filling with thermally conductive gel, a double-layer composite insulation layer, a composite shielding layer, a multi-layer sheath layer, and a honeycomb buffer layer to form a dual-channel heat dissipation system, enhancing torsional resistance and electromagnetic compatibility.
It improves the cable's anti-interference ability, enhances mechanical reliability, extends service life, and maintains efficient heat dissipation and electromagnetic compatibility performance in harsh environments.
Smart Images
Figure CN224304391U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of cable technology, specifically to a high-temperature resistant and interference-resistant power cable for high-speed rail transit. Background Technology
[0002] Traditional power cables for rail vehicles have the following problems during high-speed operation: (1) Mechanical stress: Frequent vibration and bending lead to conductor breakage and insulation wear. (2) Weak heat dissipation: The cable heats up during high-speed operation, the material becomes brittle in low-temperature environments, and the heat generated by conductor resistance loss is difficult to dissipate effectively, resulting in excessive internal temperature rise of the cable and accelerated insulation aging. (3) Electromagnetic interference: Electromagnetic coupling interference is easily generated when power cables and signal cables run in parallel. (4) Insufficient weather resistance: Long-term exposure to humid and salt spray environments leads to sheath aging. (5) Poor electromagnetic compatibility: When high-frequency interference signals generated by the frequency conversion drive system are transmitted through the cable, they are prone to signal crosstalk and equipment malfunction. Traditional single-shield design is difficult to effectively suppress broadband interference above 100MHz. Existing solutions (such as adding a shielding layer or thickening the sheath) often sacrifice the flexibility and weight of the cable, making it difficult to meet the dual requirements of lightweight and high reliability of high-speed rail. Therefore, this utility model proposes a high-temperature resistant and anti-interference power cable for high-speed rail transit to solve the shortcomings and deficiencies of the existing technology. Utility Model Content
[0003] The purpose of this utility model is to overcome the shortcomings of the existing technology and provide a high-temperature resistant and interference-resistant power cable for high-speed rail transit.
[0004] The technical solution adopted in this utility model is as follows:
[0005] A high-temperature resistant and interference-resistant power cable for high-speed rail transit includes a cable body, which comprises, from the inside out, a conductor, an insulation layer, a high-temperature resistant filling layer, a shielding layer, and a sheathing layer. The gaps between the conductors are filled with thermally conductive gel. The shielding layer is a composite structure consisting of an inner copper wire braided shield and an outer longitudinally wrapped tin-plated copper strip.
[0006] Preferably, the insulating layer has a double-layer composite structure, with the inner layer being a ceramicized silicone rubber layer and the outer layer being a highly elastic TPU layer.
[0007] Preferably, the sheath layer comprises a five-layer composite structure, consisting of, from the inside out, a modified polyurethane adhesive layer, an aramid fiber braided reinforcement layer, a conductive TPU layer, a microporous foamed silicone rubber buffer layer, and a UV-cured corrugated surface protective layer.
[0008] Preferably, an anti-torsion layer is provided between the shielding layer and the sheath layer.
[0009] Preferably, the conductor adopts a three-layer voltage divider structure, consisting of an inner layer, a middle layer, and an outer layer from the inside out.
[0010] Preferably, a honeycomb buffer layer is provided between the high-temperature resistant filling layer and the shielding layer.
[0011] The beneficial effects of this invention are: enhanced anti-interference capability, effectively suppressing conducted and radiated interference generated by the frequency conversion system; improved mechanical reliability, with the honeycomb buffer layer absorbing vibration energy, preventing stress concentration, and exhibiting high resistance to dynamic bending; the thermally conductive gel and honeycomb structure forming a dual-channel heat dissipation system, reducing the temperature of the working conductor, extending the cable's service life, and demonstrating strong environmental adaptability. Attached Figure Description
[0012] Figure 1 : A schematic diagram of the structure of this utility model.
[0013] Figure 2 : A schematic diagram of the structure of the insulating layer of this utility model.
[0014] Figure 3 : A schematic diagram of the shielding layer of this utility model.
[0015] Figure 4 : A schematic diagram of the structure of the sheath layer of this utility model. Detailed Implementation
[0016] The accompanying drawings are for illustrative purposes only and should not be construed as limiting the scope of this patent. To better illustrate this embodiment, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.
[0017] like Figure 1-4 As shown, a high-temperature resistant and interference-resistant power cable for high-speed rail transit includes a cable body. The cable body includes, from the inside out, a conductor 1, an insulation layer 2, a high-temperature resistant filling layer 3, a shielding layer 4, and a sheath layer 5. The conductor 1 is made of silver-plated annealed soft aluminum alloy conductor and adopts reverse twist conductor stranding (adjacent layers of single wires are stranded in opposite directions).
[0018] The gap between conductors 1 is filled with thermally conductive gel 1.4; the shielding layer 4 is a composite structure consisting of an inner copper wire braided shield 4.1 and an outer longitudinally wrapped tin-plated copper strip 4.2. The inner copper wire braided shield 4.1 is a 20AWG tin-plated copper wire braided layer with a density of 85%, and the outer longitudinally wrapped tin-plated copper strip 4.2 is a tin-plated copper strip with a thickness of 0.15mm and an overlap rate of ≥30%, forming a 360° continuous shielding layer.
[0019] Further optimizations to this solution include: Figure 1-4As shown, the insulating layer 2 is a double-layer composite structure. The inner layer is a ceramicized silicone rubber layer 2.1 mixed with nano boron nitride. Nano boron nitride (particle size 50nm, addition amount 8wt%) is blended with vinyl silicone rubber and molded at 180℃ to form a 2.5mm thick ceramicized layer (2.1). The outer layer is a high-elasticity TPU layer 2.2. The outer layer is coated with TPU material with a Shore hardness of 85A by extrusion process, with a thickness of 1.5mm.
[0020] Further optimizations to this solution include: Figure 1-4 As shown, the sheath layer 5 comprises a five-layer composite structure, which, from the inside out, are: a modified polyurethane adhesive layer 5.1, an aramid fiber braided reinforcement layer 5.2, a conductive TPU layer mixed with carbon nanotubes 5.3, a microporous foamed silicone rubber buffer layer 5.4, and a UV-cured corrugated surface protective layer 5.5.
[0021] The modified polyurethane adhesive layer 5.1 is a modified polyurethane containing isocyanate groups, with a thickness of 0.1 mm, which enhances the interfacial bonding force; the aramid fiber braided reinforcement layer 5.2 is 12K aramid fibers woven at an 80° cross angle, with a density of 120 fibers / 10 cm; the conductive TPU layer 5.3 is carbon nanotubes (diameter 10 nm, content 3 wt%) dispersed in the TPU matrix, with a surface resistivity ≤10^6 Ω / sq; the microporous foamed silicone rubber buffer layer 5.4 is silicone rubber chemically foamed to form a microporous structure with an average pore size of 0.3 mm and a Shore hardness of 50 A; the UV-cured corrugated surface protective layer 2.5 is an acrylic resin containing a photoinitiator UV-cured to form a 0.05 mm corrugated layer with a corrugation height of 0.2 mm and a pitch of 1.5 mm.
[0022] Further optimizations to this solution include: Figure 1-4 As shown, an anti-torsion layer 8 is provided between the shielding layer 4 and the sheath layer 6. The anti-torsion layer 8 is woven from polyimide fiber and glass fiber in a 3:1 ratio, with a thickness of 1.0 mm and a torsional stiffness of 150 N·m / rad. The honeycomb buffer layer 7 is made of polyetheretherketone (PEEK) material, with a cell size of 2 mm × 2 mm and a wall thickness of 0.1 mm, and is filled with thermally conductive silicone (thermal conductivity 2.5 W / (m·K)).
[0023] Further optimizations to this solution include: Figure 1-4 As shown, conductor 1 adopts a three-layer voltage divider structure, consisting of an inner layer (1.1), a middle layer (1.2), and an outer layer (1.3) from the inside out. The inner layer (1.1) is a bundle of silver-plated copper wire with a diameter of 0.3 mm, the middle layer (1.2) is a braided layer of tin-plated copper wire with a diameter of 0.5 mm, and the outer layer (1.3) is a spirally wound 0.8 mm non-magnetic copper alloy strip. The resistivity gradient distribution of the three layers effectively reduces the skin effect, and the DC resistance at 20℃ is ≤0.05Ω / km.
[0024] Further optimizations to this solution include: Figure 1-4As shown, a honeycomb buffer layer 7 is provided between the high-temperature resistant filling layer 3 and the shielding layer 4. The honeycomb buffer layer 7 is made of polyetheretherketone (PEEK) material, with a cell size of 2mm×2mm and a wall thickness of 0.1mm, and is filled with thermally conductive silicone (thermal conductivity 2.5W / (m・K)).
[0025] The positional relationships described in the figures are for illustrative purposes only and should not be construed as limiting this patent. Clearly, the above embodiments of this utility model are merely examples to clearly illustrate the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the scope of protection of the claims of this utility model.
Claims
1. A high-temperature resistant and interference-resistant power cable for high-speed rail transit, characterized in that: The cable body includes a conductor (1), an insulation layer (2), a high-temperature resistant filling layer (3), a shielding layer (4), and a sheath layer (5) from the inside out. The conductor (1) is filled with thermally conductive gel (1.4). The shielding layer (4) is a composite structure consisting of an inner copper wire braided shield (4.1) and an outer longitudinally wrapped tin-plated copper strip (4.2).
2. The high-temperature resistant and interference-resistant power cable for high-speed rail transit according to claim 1, characterized in that: The insulating layer (2) is a double-layer composite structure, with the inner layer being a ceramicized silicone rubber layer (2.1) and the outer layer being a highly elastic TPU layer (2.2).
3. The high-temperature resistant and interference-resistant power cable for high-speed rail transit according to claim 1, characterized in that: The sheath layer (5) comprises a five-layer composite structure, consisting of a modified polyurethane adhesive layer (5.1), an aramid fiber braided reinforcement layer (5.2), a conductive TPU layer (5.3), a microporous foamed silicone rubber buffer layer (5.4), and a UV-cured corrugated surface protective layer (5.5) from the inside out.
4. The high-temperature resistant and interference-resistant power cable for high-speed rail transit according to claim 1, characterized in that: An anti-torsion layer (6) is provided between the shielding layer (4) and the sheath layer (5).
5. The high-temperature resistant and interference-resistant power cable for high-speed rail transit according to claim 1, characterized in that: The conductor (1) adopts a three-layer voltage divider structure, consisting of an inner layer (1.1), a middle layer (1.2), and an outer layer (1.3) from the inside out.
6. The high-temperature resistant and interference-resistant power cable for high-speed rail transit according to claim 1, characterized in that: A honeycomb-shaped buffer layer (7) is provided between the high-temperature resistant filling layer (3) and the shielding layer (4).