A lightweight flexible cable

Abstract

The utility model discloses a kind of lightweight flexible cables, relate to the technical field of wire and cable.A kind of lightweight flexible cable, including by inside outward sequentially arranged bunching cable tube, reinforcing braid and outer sheath, wherein bunching cable tube includes support core tube, several groups cable core, bunching film and inner sheath, specifically, support core tube is hollow tubular structure, cable core is stranded in the circumferential side of support core tube, bunching film and inner sheath are sequentially set in the circumferential side of cable core, inner sheath is closed-cell foam structure, and reinforcing braid includes shielding layer woven from conductive polymer fiber and reinforcing layer woven from banded metal sheet.By using the above scheme, the weight of bunching cable tube and reinforcing braid can be effectively reduced under the premise of ensuring the mechanical strength of the cable, which is conducive to the lightweight of the cable.

Description

Technical Field

[0001] This utility model relates to the technical field of wires and cables, and in particular to a lightweight flexible cable. Background Technology

[0002] With the rapid development of the power industry and the acceleration of urbanization, power cables have been widely used in power systems due to their advantages such as not being limited by elevation differences, easy installation, laying, and maintenance, and have basically replaced traditional overhead power lines in cities.

[0003] Currently, the traditional ordinary cable structure generally involves twisting a group of conductors with extruded insulation together to form the cable core, and then extruding the outer sheath. This type of cable structure not only has poor mechanical strength but also low stability, making it prone to breakage under external impact. It is difficult to provide a guarantee for long-term stable operation of the cable. Therefore, in existing technologies, some manufacturers add some additional support structures or reinforcing layers, such as steel tape armor, steel wire armor, and reinforcing rings, to improve the mechanical strength of the cable.

[0004] While these structures can significantly improve the mechanical strength and stability of cables, they undoubtedly increase the overall weight and complexity of the cables. This not only makes the cables heavier, indirectly increasing the difficulty of transportation and installation, but also affects the cable's flexibility, causing insulation tearing or core breakage during continuous and frequent torsion and bending. Therefore, further reducing the overall weight of cables while improving their flexibility, while ensuring that they possess the mechanical strength required for use, is of great significance to the development of wires and cables. Utility Model Content

[0005] In order to further reduce the overall weight of the cable while maintaining its mechanical strength, and at the same time improve its flexibility, thereby achieving lightweight and flexible cable, this application provides a lightweight flexible cable.

[0006] The lightweight flexible cable provided in this application adopts the following technical solution:

[0007] A lightweight flexible cable includes a bundled cable tube, a reinforcing braided layer, and an outer sheath arranged from the inside out.

[0008] The bundled cable tube includes a support core tube, several sets of cable cores, a bundled membrane, and an inner sheath. The support core tube is a hollow tubular structure. The several sets of cable cores are concentrically twisted around the periphery of the support core tube. The bundled membrane is wound around and covers the periphery of the cable cores. The inner sheath covers the periphery of the bundled membrane, and the inner sheath is a closed-cell foam structure.

[0009] The reinforcing braided layer includes a shielding layer and a reinforcing layer. The shielding layer is woven from conductive polymer fibers, and the reinforcing layer is woven from strip-shaped metal sheets.

[0010] By adopting the above technical solutions, using a hollow tubular support core tube as the central axis of the cable core, the weight of the bundled cable tube can be effectively reduced compared to the solid core tube of traditional cables. Furthermore, the hollow tubular structure also allows the support core tube to have higher deformability, which is beneficial for improving the flexibility of the bundled cable tube. In addition, using conductive polymer fibers instead of traditional metal fibers to form the shielding layer, and using a braided strip of metal sheet to replace the traditional armor tape layer, can effectively reduce the weight of the reinforcing braid layer. This further helps to reduce the overall weight of the cable while ensuring its mechanical strength, thus achieving cable lightweighting.

[0011] Optionally, a structural support strip is embedded on the inner side of the support core tube, and the structural support strip extends in a spiral shape along the extension direction of the support core tube.

[0012] By adopting the above technical solution, the mechanical strength and bending modulus of the support core tube are improved, making it less prone to collapse due to cable bending. Furthermore, because the structural support bars extend in a spiral shape, when the cable bends or twists, the support core tube, acting as the cable's central axis, can absorb the bending stress of the bundled cable tube through the elastic deformation of the structural support bars. Simultaneously, multiple sets of cable cores are concentrically twisted around the periphery of the support core tube, allowing the cable to repeatedly bend within the minimum bending radius without easily breaking, thus improving the flexibility and mechanical strength of the bundled cable tube.

[0013] Optionally, the cable core includes a conductor and a cable core separator covering the outside of the conductor. The conductor is formed by covering the core wire with a thin copper sheet. The core wire is formed by twisting several copper wires and silver-plated aluminum-magnesium alloy wires together. The cable core separator has a closed-cell foam structure.

[0014] By adopting the above technical solution, copper wire and silver-plated aluminum-magnesium alloy wire are twisted together to form the core wire in the cable core. Compared with pure copper solid conductor or pure copper wire stranded core wire, it has a lower overall density. Combined with the cable core separator with closed-cell foam structure, it is beneficial to further reduce the unit weight of the cable core and realize the lightweighting of the bundled cable tube.

[0015] Optionally, flame-retardant cotton yarn is filled between the cable core and the bundled membrane, and the filling density of the flame-retardant cotton yarn is 20%-40%.

[0016] By adopting the above technical solutions, not only can the flame retardant performance of the bundled cable tube be improved, but the 20%-40% filling density can also make the bundled cable tube have a certain degree of compactness, while retaining good flexibility and light weight, thus achieving the lightweighting of the bundled cable tube.

[0017] Optionally, a magnetically conductive layer is provided on the side of the bundled film facing the cable core, and the magnetically conductive layer is formed by depositing magnetic powder on the surface of the bundled film through a magnetron sputtering process.

[0018] By adopting the above technical solution, as the bundled film is wound and wrapped around the periphery of the cable core, the magnetic conductive layer of the bundled film can effectively shield low-frequency magnetic fields from the bundled cable tube or the external environment, which helps to reduce the impact of low-frequency magnetic fields on cable signal transmission. In addition, the combination of a shielding layer woven from conductive polymer fibers and a reinforcing layer woven from strip-shaped metal sheets further improves the electromagnetic shielding performance of the cable.

[0019] Optionally, the braiding angle of the shielding layer is 45°-60°, and the braiding coverage is 80%-85%.

[0020] By adopting the above technical solutions, it is beneficial to achieve cable weight reduction while ensuring that the shielding layer has a certain shielding effect.

[0021] Optionally, the reinforcing layer is a triaxial, bidirectional braided structure, including a forward spiral covering strip, a reverse spiral covering strip, and an axial reinforcing strip. The forward spiral covering strip and the reverse spiral covering strip are interwoven in an up-down manner. The axial reinforcing strip extends along the extension direction of the bundled cable tube and is evenly distributed along the outer circumference of the shielding layer. The axial reinforcing strip passes through the hollow position formed by the interweaving of the forward spiral covering strip and the reverse spiral covering strip.

[0022] By adopting the above technical solution, compared with the traditional overall armor layer, the triaxial two-way braided structure formed by strip metal sheets can not only significantly reduce the amount of metal sheets used while achieving uniform coverage and thus making the cable lighter, but also the axial reinforcing strips extending along the extension direction of the bundled cable tube can effectively improve the longitudinal modulus of the cable, which is beneficial to improving the overall axial mechanical strength of the cable.

[0023] Optionally, the number of axial reinforcing strips is 12-16, and the number of the forward-swirling covering strips and the number of the reverse-swirling covering strips are each half the number of axial reinforcing strips.

[0024] By adopting the above technical solution and setting 12-16 sets of axial reinforcing strips, the reinforcing layer can uniformly cover the shielding layer without being too dense. This is beneficial for the cable to retain good flexibility when the reinforcing layer strengthens the cable.

[0025] In summary, the technical solution of this application has at least one of the following beneficial effects:

[0026] 1. By using a hollow tubular support core tube as the central axis of the cable core, and in conjunction with structural support bars embedded in the inner wall of the support core tube, not only can the weight of the bundled cable tube be effectively reduced, but the support core tube can also have high deformability and bending modulus, which is conducive to achieving lightweight and flexible cable while ensuring the mechanical strength of the cable.

[0027] 2. By using copper wire and silver-plated aluminum-magnesium alloy wire twisted together as the core wire in the cable core, the cable core can have a lower density. Combined with the cable core separator and inner sheath with closed-cell foam structure, it is beneficial to further reduce the unit weight of the cable core and realize the lightweighting of the bundled cable tube.

[0028] 3. By using conductive polymer fibers instead of traditional metal fibers to form the shielding layer, and by using strip-shaped metal sheet braided reinforcement layers instead of traditional armor tape layers, the weight of the reinforcement braided layers can be effectively reduced. This also helps to further reduce the overall weight of the cable while ensuring its mechanical strength, thus achieving cable lightweighting. Attached Figure Description

[0029] Figure 1 This is a cross-sectional view of a lightweight flexible cable according to an embodiment of this application.

[0030] Figure 2 This is a side view of a lightweight flexible cable according to an embodiment of this application.

[0031] Figure 3 This is a cross-sectional view of the bundle membrane of a lightweight flexible cable according to an embodiment of this application.

[0032] Explanation of reference numerals in the attached figures:

[0033] 1. Bundled cable tube; 11. Supporting core tube; 111. Structural support bar; 12. Cable core; 121. Conductor; 122. Cable core separator; 13. Bundled membrane; 131. Magnetic conductive layer; 14. Inner sheath; 15. Flame-retardant cotton yarn; 2. Reinforcing braided layer; 21. Shielding layer; 22. Reinforcing layer; 221. Forward spiral wrapping tape; 222. Reverse spiral wrapping tape; 223. Axial reinforcing tape; 3. Outer sheath. Detailed Implementation

[0034] The following is in conjunction with the appendix Figures 1-3 This application will be described in further detail.

[0035] This application discloses a lightweight flexible cable. (Refer to...) Figure 1 and Figure 2 A lightweight flexible cable includes a bundled cable tube 1, a reinforcing braided layer 2, and an outer sheath 3 arranged sequentially from the inside out.

[0036] Reference Figure 1 andFigure 2 The bundled cable tube 1 includes a supporting core tube 11, several sets of cable cores 12, a bundled membrane 13, and an inner sheath 14. The supporting core tube 11 is a hollow tubular structure. Structural support bars 111 are embedded inside the tube wall to improve the mechanical strength of the supporting core tube 11. These structural support bars 111 extend spirally along the extension direction of the supporting core tube 11, thereby enhancing its mechanical strength. Several sets of cable cores 12 are concentrically twisted around the periphery of the supporting core tube 11. The bundled membrane 13 is wound around the periphery of the cable cores 12 in the opposite direction to the twisting of the cable cores 12. The inner sheath 14 is made of insulating rubber and is extruded onto the periphery of the bundled membrane 13, thus forming a bundled cable tube 1 with a circular cross-section.

[0037] Reference Figure 1 and Figure 2 The cable core 12 includes a conductor 121 and a cable core separator 122. The cable core separator 122 is also made of insulating rubber and is wrapped around the conductor 121 by an extrusion coating process. In this embodiment, the conductor 121 is specifically made of a core wire wrapped with a thin copper sheet. The core wire is made of several copper wires and silver-plated aluminum-magnesium alloy wires twisted together. The mixing ratio of copper wires and silver-plated aluminum-magnesium alloy wires is 7:3. Compared with a pure copper solid conductor 121 or a pure copper wire stranded core wire, the overall density of the conductor 121 in this embodiment is reduced by 25-40%, which helps to reduce the overall weight of the cable core 12 and achieve the lightweighting of the bundled cable tube 1.

[0038] In addition, in this embodiment, both the cable core separator 122 and the inner sheath 14 are made of foamed silicone rubber and have a closed-cell foam structure. This ensures that the cable core separator 122 and the inner sheath 14 have a certain degree of flexibility and electrical insulation while significantly reducing the weight of the bundled cable tube 1, thus achieving lightweighting of the bundled cable tube 1.

[0039] Reference Figure 1 The bundled cable tube 1 is also filled with flame-retardant cotton yarn 15. Specifically, the flame-retardant cotton yarn 15 is filled between the cable core 12 and the bundled film 13, and in this embodiment, the filling density of the flame-retardant cotton yarn 15 is 30%. The flame-retardant cotton yarn 15 not only improves the flame-retardant performance of the bundled cable tube 1 itself, but the 30% filling density also enables the bundled cable tube 1 to have a certain degree of compactness, while retaining good flexibility and light weight.

[0040] Reference Figure 1 and Figure 3The surface of the bundled film 13 facing the cable core 12 is further provided with a magnetic conductive layer 131. Specifically, the magnetic conductive layer 131 is formed by depositing magnetic powder onto the surface of the bundled film 13 by magnetron sputtering. The magnetic powder can be at least one of ferrite powder, iron-cobalt alloy, cobalt-nickel alloy, and nickel-zinc ferrite magnetic powder. In this embodiment, the magnetic powder is specifically ferrite powder. Thus, as the bundled film 13 is wound around and covers the periphery of the cable core 12, the magnetic conductive layer 131 of the bundled film 13 can effectively shield low-frequency magnetic fields from the bundled cable tube 1 or the external environment, which helps to reduce the impact of low-frequency magnetic fields on cable signal transmission.

[0041] Reference Figure 1 and Figure 2 The reinforcing braided layer 2 includes a shielding layer 21 and a reinforcing layer 22. The shielding layer 21 is used to reduce the influence of electromagnetic fields on the normal operation of the cable, while the reinforcing layer 22 is mainly used to enhance the overall mechanical strength and tensile strength of the cable.

[0042] Specifically, the shielding layer 21 is woven from conductive polymer fibers, which can be selected from silver-plated nylon fibers, copper-plated polyester fibers, polythiophene fibers, polyaniline fibers, or carbon fibers. In this embodiment, the conductive polymer fiber is polythiophene fiber. Compared with traditional metal fibers, conductive polymer fibers have low density and high flexibility, which helps to prevent cracks or breaks in the reinforcing braided layer 2 after repeated bending and twisting of the cable, while also achieving cable lightweighting.

[0043] Furthermore, in order to achieve cable weight reduction while ensuring that the shielding layer 21 has a certain electromagnetic shielding effect, the braiding angle of the shielding layer 21 can be selected within the range of 45°-60° according to the braiding pattern, and the braiding coverage of the shielding layer 21 is 80%-85%. In this embodiment, the braiding angle of the shielding braiding layer is 60°, and the braiding coverage is 85%.

[0044] Reference Figure 1 and Figure 2The reinforcing layer 22 is woven from strip-shaped metal sheets around the periphery of the shielding layer 21, wherein the reinforcing layer 22 has a triaxial bidirectional braided structure. Specifically, the strip-shaped metal sheets are strip-shaped aluminum sheets with a thickness of 0.2 mm. The reinforcing layer 22 includes a clockwise spiral covering strip 221, a counterclockwise spiral covering strip 222, and an axial reinforcing strip 223. The clockwise spiral covering strip 221 and the counterclockwise spiral covering strip 222 are wound and wrapped around the surface of the shielding layer 21 in a clockwise and counterclockwise direction, respectively, and the clockwise spiral covering strip 221 and the counterclockwise spiral covering strip 222 are interwoven in an up-down manner. The axial reinforcing strip 223 extends along the extension direction of the bundled cable tube 1 and is evenly distributed along the outer circumference of the shielding layer 21. The axial reinforcing strip 223 passes through the hollow position formed by the interlacing of the forward spiral covering strip 221 and the reverse spiral covering strip 222, but does not participate in the interlacing of the forward spiral covering strip 221 and the reverse spiral covering strip 222. In this embodiment, a total of 16 axial reinforcing strips 223 are provided, and 8 forward spiral covering strips 221 and 8 reverse spiral covering strips 222 are provided respectively. In other embodiments, the number of axial reinforcing strips 223 is 12-16, and the number of forward spiral covering strips 221 and reverse spiral covering strips 222 is kept at half the number of axial reinforcing strips 223. Thus, the axial reinforcing strip 223 can be tightly wrapped around the surface of the shielding layer 21 by the forward spiral wrapping strip 221 and the reverse spiral wrapping strip 222, which can effectively improve the overall axial mechanical strength of the cable. Moreover, the triaxial two-way braided structure can make the strip metal sheet uniformly wrap around the shielding layer 21, which is conducive to further improving the electromagnetic shielding effect of the cable.

[0045] Reference Figure 1 and Figure 2 The outer sheath 3 is formed by extruding and coating high-toughness insulating rubber onto the outer periphery of the torsion buffer layer and then curing it. Polyurethane rubber is specifically selected. Therefore, when the cable is bent or twisted, the highly flexible outer sheath 3 is not easily torn, which helps to improve the overall flexibility and service life of the cable.

[0046] The implementation principle of a lightweight flexible cable in this application embodiment is as follows:

[0047] By using a hollow tubular support core tube 11 as the central axis of the cable core 12, the weight of the bundled cable tube 1 can be effectively reduced compared to the solid core shaft of traditional cables. Moreover, the hollow tubular structure also allows the support core tube 11 to have high deformability, which is beneficial to improving the flexibility of the bundled cable tube 1 and enhancing the flexibility of the cable.

[0048] By using copper wire and silver-plated aluminum-magnesium alloy wire twisted together as the core wire in the cable core 12, it has a lower overall density compared to pure copper solid conductor 121 or pure copper wire stranded core wire. Combined with the cable core separator 122 with closed-cell foam structure and inner sheath 14, it is beneficial to further reduce the unit weight of the cable core 12 and achieve the lightweighting of the bundled cable tube 1.

[0049] In addition, by using conductive polymer fibers instead of traditional metal fibers to form the shielding layer 21, and by using a reinforcing layer 22 woven from strip-shaped metal sheets instead of the traditional armor tape layer, the weight of the reinforcing braided layer 2 can be effectively reduced. This also helps to further reduce the overall weight of the cable while ensuring the mechanical strength of the cable, thus achieving cable lightweighting.

[0050] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this specific embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of this application.

Claims

1. A lightweight flexible cable, characterized in that: It includes a bundled cable tube (1), a reinforcing braided layer (2), and an outer sheath (3) arranged from the inside out; The bundled cable tube (1) includes a support core tube (11), several sets of cable cores (12), a bundled membrane (13), and an inner sheath (14). The support core tube (11) is a hollow tubular structure. Several sets of cable cores (12) are twisted together concentrically around the support core tube (11). The bundled membrane (13) is wrapped around the cable cores (12). The inner sheath (14) is wrapped around the bundled membrane (13). The inner sheath (14) is a closed-cell foam structure. The reinforcing braided layer (2) includes a shielding layer (21) and a reinforcing layer (22). The shielding layer (21) is woven from conductive polymer fibers, and the reinforcing layer (22) is woven from strip-shaped metal sheets.

2. The lightweight flexible cable according to claim 1, characterized in that: The inner wall of the supporting core tube (11) is provided with a structural support strip (111), which extends in a spiral shape along the extension direction of the supporting core tube (11).

3. The lightweight flexible cable according to claim 1, characterized in that: The cable core (12) includes a conductor (121) and a cable core partition (122) covering the outside of the conductor (121). The conductor (121) is formed by covering the core wire with a thin copper sheet. The core wire is formed by twisting several copper wires with silver-plated aluminum-magnesium alloy wires. The cable core partition (122) is a closed-cell foam structure.

4. The lightweight flexible cable according to claim 1, characterized in that: Flame-retardant cotton yarn (15) is filled between the cable core (12) and the bundled membrane (13), and the filling density of the flame-retardant cotton yarn (15) is 20%-40%.

5. A lightweight flexible cable according to claim 1, characterized in that: The bundled film (13) has a magnetic conductive layer (131) on the side facing the cable core (12). The magnetic conductive layer (131) is formed by magnetic powder being deposited on the surface of the bundled film (13) by magnetron sputtering.

6. A lightweight flexible cable according to claim 1, characterized in that: The shielding layer (21) has a weaving angle of 45°-60° and a weaving coverage of 80%-85%.

7. A lightweight flexible cable according to claim 1, characterized in that: The reinforcing layer (22) is a triaxial bidirectional braided structure, including a forward spiral covering strip (221), a reverse spiral covering strip (222), and an axial reinforcing strip (223). The forward spiral covering strip (221) and the reverse spiral covering strip (222) are interwoven in an up-down manner. The axial reinforcing strip (223) extends along the extension direction of the bundled cable tube (1) and is evenly distributed along the outer circumference of the shielding layer (21). The axial reinforcing strip (223) is inserted into the hollow position formed by the interweaving of the forward spiral covering strip (221) and the reverse spiral covering strip (222).

8. A lightweight flexible cable according to claim 7, characterized in that: The number of axial reinforcing strips (223) is 12-16, and the number of positive spiral covering strips (221) and negative spiral covering strips (222) is half the number of axial reinforcing strips (223).

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