A double capacity low sag overhead cable
By designing an integrated structure of the central frame and power conductor core, the problems of large sag and limited current carrying capacity of overhead insulated cables were solved, achieving low sag and high current carrying capacity, thus improving the construction efficiency of long-span lines and the applicability of the power grid.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- QUJING CABLE CO LTD
- Filing Date
- 2025-06-05
- Publication Date
- 2026-06-09
AI Technical Summary
Existing overhead insulated cables have shortcomings in terms of sag and current carrying capacity. Large sag leads to insufficient safety distance and high construction costs, while limited current carrying capacity cannot meet high load requirements.
Design a high-capacity, low-sag overhead cable that adopts a comprehensive structure consisting of a central frame, signal conductors, power conductors, an isolation layer, a stabilizing element, and a sheath. The design of the central frame reduces sag, and the use of two power conductors increases current carrying capacity.
It significantly reduces sag, improves the safety and stability of long-span lines, reduces construction costs, and meets the increasing demand of power grid load.
Smart Images
Figure CN224342070U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of high-capacity cable technology, and in particular to a high-capacity low-sag overhead cable. Background Technology
[0002] Overhead insulated cables are a special type of cable that lies between an overhead conductor and a ground wire. They are widely used in power transmission and distribution in urban power distribution networks, mountain transmission lines, coastal transmission lines, wind farms, high-altitude transmission lines, transmission lines crossing different areas, and power distribution automation systems.
[0003] With the continuous development of society and the economy, the trend towards intelligent and economical power grid integration is becoming increasingly urgent. In practical applications, existing overhead insulated cables mainly suffer from the following two shortcomings:
[0004] 1. Large Sag. Due to its larger weight limit (greater than that of bare overhead wires of the same specifications), the cable exhibits significant sag. This sag results in insufficient safe distance between the line and the ground or other obstacles, making it unsuitable for long-span lines. Furthermore, larger sag requires more complex installation and maintenance measures, increasing construction costs and time. For example, in scenarios crossing rivers, valleys, or railways, taller poles are needed to ensure sufficient safe distance. In addition, larger sag can cause significant swaying of the cable in windy conditions, affecting line stability and safety.
[0005] Second, current-carrying capacity is limited. The insulation material of overhead insulated cables has certain physical temperature limitations. When the cable operates under high load, the temperature of the insulation layer will rise. Overheating not only reduces the cable's service life but also leads to a decline in the insulation performance of the insulation layer, increasing the risk of failure. It cannot adapt to the high-load operation requirements under high-temperature climatic conditions. For example, in areas with high summer temperatures or concentrated industrial loads, the current-carrying capacity of cables is limited, making it difficult to meet electricity demand. Simultaneously, with the continuous increase in grid load, the current-carrying capacity of existing overhead insulated cables cannot meet the urgent requirement of grid capacity expansion. The insulation material of existing cables limits their current-carrying capacity increase, making it impossible to achieve this goal.
[0006] Chinese patent CN220709970U discloses a low-sag, high-capacity conductor. This patent uses high-strength stranded carbon fiber as a load-bearing component, leveraging its low coefficient of thermal expansion to increase the conductor's sag, thereby transmitting more electrical energy. However, this conductor is a bare wire and cannot be used to improve overhead insulated cables. Furthermore, the stranded carbon fiber is a resin-filled organic composite material, and its fracture mechanism is inelastic brittle fracture, so its safety performance still lacks reliable verification.
[0007] Therefore, how to provide an overhead insulated cable that improves both sag performance and current carrying capacity has become an urgent technical problem to be solved. Utility Model Content
[0008] In view of this, in order to overcome the shortcomings of the prior art, this application aims to provide a high-capacity, low-sag overhead cable.
[0009] This application provides a high-capacity, low-sag overhead cable, which includes a central frame, two signal cores, two power cores, an isolation layer, multiple first stabilizing members, multiple second stabilizing members, a shielding layer, and an outer sheath. The two signal cores are symmetrically distributed on the inner sides of both ends of the central frame, and the two power cores are symmetrically distributed on both sides of the central frame. The isolation layer is disposed on the outer side of the central frame and the power cores. Multiple first stabilizing members are distributed one-to-one in the cavity formed by the isolation layer, the central frame, and the power cores. Multiple second stabilizing members are distributed one-to-one in the cavity formed by the central frame, the power cores, and the first stabilizing members. The shielding layer and the outer sheath are sequentially disposed on the outer side of the isolation layer.
[0010] Optionally, in the high-capacity low-sag overhead cable of this application, the cross-section of the central frame is generally elongated, the width of the central frame decreases from the ends to the center, and assembly channels are provided at both ends of the central frame.
[0011] Optionally, in the high-capacity low-sag overhead cable of this application, the cross-section of the assembly channel is composed of two mutually perpendicular ellipses.
[0012] Optionally, in the high-capacity low-sag overhead cable of this application, arc-shaped grooves recessed towards the center are provided on both sides of the central frame.
[0013] Optionally, in the high-capacity low-sag overhead cable of this application, a first stabilizing member and a second stabilizing member are respectively provided on both sides of the end of the central frame.
[0014] Optionally, in the high-capacity low-sag overhead cable of this application, a flexible channel is provided at the center of the central frame.
[0015] Optionally, in the high-capacity low-sag overhead cable of this application, the cross-section of the elastic channel is elliptical, and the major axis of the ellipse is collinear with the center of the assembly channel at both ends of the central frame.
[0016] Optionally, in the high-capacity low-sag overhead cable of this application, the signal core includes a signal core conductor and, from the inside out, an inner shielding layer, an inner insulation layer, an outer shielding layer, and an outer insulation layer that are sequentially wrapped around the outside of the signal core conductor.
[0017] Optionally, in the high-capacity low-sag overhead cable of this application, the power core includes a load-bearing member and a power conductor and a power insulation layer sequentially disposed outside the load-bearing member.
[0018] Optionally, in the high-capacity low-sag overhead cable of this application, the power conductor is made of multiple conductor monofilaments with trapezoidal cross-sections twisted together.
[0019] The high-capacity, low-sag overhead cable of this application, through comprehensive structural design, has the following beneficial technical effects:
[0020] I. Significantly reduce sag and improve the applicability of long-span lines
[0021] To ensure a safe distance between the line and the ground or other obstacles and avoid safety hazards caused by excessive sag, the sag under its own weight is significantly reduced. For example, in scenarios such as crossing rivers, valleys, or railways, sufficient safe distances can be guaranteed without building taller towers, greatly reducing construction costs and time, and improving construction efficiency.
[0022] II. Enhanced wind resistance performance
[0023] This significantly reduces the sway amplitude caused by wind, thereby effectively improving the stability and safety of the line. Even under severe weather conditions such as strong winds, the cable can maintain stable operation, reducing the risk of line failures caused by wind swaying and further enhancing the applicability and reliability of long-span lines.
[0024] III. Increase current carrying capacity to meet the grid capacity doubling requirements.
[0025] By simultaneously installing two load-bearing power conductors within a single cable, the cable's sag characteristics and transmission capacity are improved, enabling the cable to be used in longer-span installations. This is especially suitable for lines requiring increased transmission capacity but with high requirements for the sag performance of transmission components, effectively meeting the growing demand of the power grid and providing strong support for doubling the grid's capacity. Attached Figure Description
[0026] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0027] Figure 1 This is a structural example diagram of a high-capacity, low-sag overhead cable according to an embodiment of this application;
[0028] Figure 2This is a structural example diagram of the central frame of a high-capacity, low-sag overhead cable according to an embodiment of this application;
[0029] Figure 3 This is a structural example diagram of the signal core of a high-capacity, low-sag overhead cable according to an embodiment of this application;
[0030] Figure 4 This is an example diagram illustrating the structure of the power conductor core of a high-capacity, low-sag overhead cable according to an embodiment of this application.
[0031] In the diagram, 1-central frame, 2-signal wire core, 3-power wire core, 4-isolation layer, 5-first stabilizing component, 6-second stabilizing component, 7-shielding layer, 8-outer sheath, 11-end, 12-arc groove, 13-assembly channel, 14-elastic channel, 21-signal wire core conductor, 22-inner shielding layer of signal wire core, 23-inner insulation layer of signal wire core, 24-outer shielding layer of signal wire core, 25-outer insulation layer of signal wire core, 31-load-bearing component, 32-power conductor, 33-power insulation layer. Detailed Implementation
[0032] The embodiments of this application will now be described in detail with reference to the accompanying drawings.
[0033] It should be noted that, in the absence of conflict, the following embodiments and features can be combined with each other; and, based on the embodiments of this disclosure, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this disclosure.
[0034] It should be noted that various aspects of embodiments within the scope of the appended claims are described below. It will be apparent that the aspects described herein can be embodied in a wide variety of forms, and any particular structure and / or function described herein is merely illustrative. Based on this disclosure, those skilled in the art will understand that one aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number of aspects set forth herein can be used to implement the device and / or practice the method. Additionally, this device and / or method can be implemented using structures and / or functionalities other than one or more of the aspects set forth herein.
[0035] Figure 1 This is a structural example diagram of a high-capacity, low-sag overhead cable according to an embodiment of this application, as shown below. Figure 1As shown, in this embodiment, the double-capacity low-sag overhead cable includes a central frame 1, two signal cores 2, two power cores 3, an isolation layer 4, multiple first stabilizing members 5, multiple second stabilizing members 6, a shielding layer 7, and an outer sheath 8. The signal cores 2 are symmetrically distributed on the inner sides of both ends of the central frame 1, and the power cores 3 are symmetrically distributed on both sides of the central frame 1. The isolation layer 4 is disposed on the outer side of the central frame 1 and the power cores 3. Multiple first stabilizing members 5 are distributed one-to-one in the cavity formed by the isolation layer 4, the central frame 1, and the power cores 3. Multiple second stabilizing members 6 are distributed one-to-one in the cavity formed by the central frame 1, the power cores 3, and the first stabilizing members 5. The shielding layer 7 and the outer sheath 8 are sequentially disposed on the outer side of the isolation layer 4.
[0036] As an optional example, in this embodiment of the double-capacity low-sag overhead cable, a first stabilizing member 5 and a second stabilizing member 6 are respectively provided on both sides of the end 11 of the central frame 1. In this embodiment, the first stabilizing member 5 and the second stabilizing member 6 are hollow tubes, which can be made of materials with excellent mechanical and physical properties, electrical insulation properties, and high and low temperature resistance, such as cross-linked polyethylene, silicone rubber, and polyvinyl chloride, according to the specific scenario parameters of the actual line installation. The first stabilizing member 5 and the second stabilizing member 6 can provide deformation space for the internal components while ensuring stable assembly between the internal components, significantly improving the flexibility and bending performance of the overall components and reducing the bending radius. When the double-capacity low-sag overhead cable is manufactured, transported, installed, and in service, the internal transmission components are reliably protected and will not be damaged due to bending or torsion. Especially during service, the structural design in this embodiment can significantly improve the overall vibration resistance of the double-capacity low-sag overhead cable.
[0037] Figure 2 This is a structural example diagram of the central frame of a high-capacity, low-sag overhead cable according to an embodiment of this application, as shown below. Figure 1 and Figure 2 As shown, in this embodiment, the cross-section of the central frame 1 is generally elongated, and the width of the central frame 1 decreases from the end 11 towards the center. As an optional example, in this embodiment, arc-shaped grooves 12 recessed towards the center are provided on both sides of the central frame 1. In practical applications, the structural design of the central frame 1 in this embodiment can provide a stable assembly space and reasonable deformation or movement space for the power conductor 3, the first stabilizing member 5, and the second stabilizing member 6.
[0038] Assembly channels 13 are provided at both ends of the central frame 1. As an optional example, in this embodiment, the cross-section of the assembly channel 13 is composed of two mutually perpendicular ellipses. In practical applications, the signal cores 2 are assembled one-to-one in the assembly channels 13 of the central frame 1. The cross-sectional design of the assembly channels 13 can ensure the vibration resistance and impact resistance of the central frame 1 while stabilizing the assembly of the signal cores 2. When the high-capacity, low-sag overhead cable of this embodiment is subjected to external loads or vibrations, the central frame 1 can absorb some of the energy through its own deformation, thereby reducing the impact of external loads on the signal cores 2.
[0039] In this embodiment, to further improve the vibration resistance and flexibility of the central frame 1, an elastic channel 14 is provided at the center of the central frame 1. The cross-section of the elastic channel 14 is elliptical, and the major axis of the ellipse is collinear with the center of the assembly channels 13 at both ends of the central frame 1. In this embodiment, the central frame 1 can be made of organic polymer materials with excellent mechanical and physical properties, electrical insulation properties, and low density, such as silicone rubber, cross-linked polyolefin, cross-linked polyethylene, polyetheretherketone, polypropylene, etc.
[0040] Figure 3 This is an example diagram illustrating the structure of the signal core of a high-capacity, low-sag overhead cable according to an embodiment of this application. Figure 1 , Figure 2 and Figure 3 As shown, in this embodiment, the signal core 2 includes a signal core conductor 21 and, from the inside out, an inner shielding layer 22, an inner insulation layer 23, an outer shielding layer 24, and an outer insulation layer 25, which are sequentially wrapped around the outer side of the signal core conductor 21. In practical applications, the components of the signal core 2 can be specifically selected according to the parameter requirements of the line transmission. For example, the signal core conductor 21 can be made of annealed soft copper wire, or other suitable materials such as tin-plated copper wire; the inner shielding layer 22 can be made of a semi-conductive polymer, such as semi-conductive cross-linked polyethylene; the inner insulation layer 23 can be made of a polymer material with excellent physical and mechanical properties and electrical insulation performance, such as cross-linked polyethylene or cross-linked polyolefin; the outer shielding layer 24 can be made of a semi-conductive film, such as semi-conductive paper tape or semi-conductive metal composite film; and the outer insulation layer 25 can be made by extrusion molding of polyvinyl chloride.
[0041] Figure 4 This is an example diagram illustrating the structure of the power conductor core of a high-capacity, low-sag overhead cable according to an embodiment of this application. Figure 1 and Figure 4As shown, in this embodiment, the power conductor 3 includes a load-bearing member 31 and a power conductor 32 and a power insulation layer 33 sequentially disposed outside the load-bearing member 31. In this embodiment, the power conductor 32 is made of multiple conductor monofilaments with trapezoidal cross-sections twisted together. It should be noted that this embodiment improves the sag characteristics and transmission capacity of the cable by simultaneously setting two power conductors 3 with load-bearing members 31 within a single cable, making the cable suitable for erected lines with larger spans, especially suitable for lines that require increased transmission capacity but have high requirements for the sag performance of transmission components.
[0042] The high-capacity, low-sag overhead cable of this embodiment, through comprehensive structural design, has the following beneficial technical effects:
[0043] I. Significantly reduce sag and improve the applicability of long-span lines
[0044] To ensure a safe distance between the line and the ground or other obstacles and avoid safety hazards caused by excessive sag, the sag under its own weight is significantly reduced. For example, in scenarios such as crossing rivers, valleys, or railways, sufficient safe distances can be guaranteed without building taller towers, greatly reducing construction costs and time, and improving construction efficiency.
[0045] II. Enhanced wind resistance performance
[0046] This significantly reduces the sway amplitude caused by wind, thereby effectively improving the stability and safety of the line. Even under severe weather conditions such as strong winds, the cable can maintain stable operation, reducing the risk of line failures caused by wind swaying and further enhancing the applicability and reliability of long-span lines.
[0047] III. Increase current carrying capacity to meet the grid capacity doubling requirements.
[0048] By simultaneously installing two load-bearing power conductors within a single cable, the cable's sag characteristics and transmission capacity are improved, enabling the cable to be used in longer-span installations. This is especially suitable for lines requiring increased transmission capacity but with high requirements for the sag performance of transmission components, effectively meeting the growing demand of the power grid and providing strong support for doubling the grid's capacity.
[0049] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.
Claims
1. A high-capacity, low-sag overhead cable, characterized in that, The high-capacity, low-sag overhead cable includes a central frame, two signal cores, two power cores, an isolation layer, multiple first stabilizing members, multiple second stabilizing members, a shielding layer, and an outer sheath. The two signal cores are symmetrically distributed on the inner sides of both ends of the central frame, and the two power cores are symmetrically distributed on both sides of the central frame. The isolation layer is located on the outer side of the central frame and the power cores. Multiple first stabilizing members are distributed one-to-one in the cavity formed by the isolation layer, the central frame, and the power cores. Multiple second stabilizing members are distributed one-to-one in the cavity formed by the central frame, the power cores, and the first stabilizing members. The shielding layer and the outer sheath are sequentially located on the outer side of the isolation layer.
2. The high-capacity, low-sag overhead cable according to claim 1, characterized in that, The cross-section of the central frame is generally elongated, and the width of the central frame decreases from the ends to the center. Assembly channels are set at both ends of the central frame.
3. The high-capacity, low-sag overhead cable according to claim 2, characterized in that, The cross-section of the assembly channel is composed of two mutually perpendicular ellipses.
4. The high-capacity, low-sag overhead cable according to claim 3, characterized in that, The central frame has concave arc-shaped grooves on both sides.
5. The high-capacity, low-sag overhead cable according to claim 4, characterized in that, A first stabilizing member and a second stabilizing member are respectively installed on both sides of the end of the central frame.
6. The high-capacity, low-sag overhead cable according to claim 5, characterized in that, A flexible passage is set in the center of the central frame.
7. The high-capacity, low-sag overhead cable according to claim 6, characterized in that, The cross-section of the flexible channel is elliptical, and the major axis of the ellipse is collinear with the center of the assembly channels at both ends of the central frame.
8. The high-capacity, low-sag overhead cable according to claim 1, characterized in that, The signal core includes a signal core conductor and, from the inside out, an inner shielding layer, an inner insulation layer, an outer shielding layer, and an outer insulation layer that are sequentially wrapped around the outside of the signal core conductor.
9. The high-capacity, low-sag overhead cable according to claim 1, characterized in that, The power conductor core includes a load-bearing component and a power conductor and a power insulation layer arranged sequentially on the outside of the load-bearing component.
10. The high-capacity, low-sag overhead cable according to claim 1, characterized in that, Electric conductors are made by twisting together multiple conductor monofilaments with trapezoidal cross-sections.