A corrugated conductive core optimized copper alloy cable
By using copper alloy cables with a corrugated structure and optimized materials, the contradiction between flexibility and strength in traditional cables has been resolved, resulting in a cable design with high strength, corrosion resistance, and flame retardancy.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SICHUAN WANYANG CABLE
- Filing Date
- 2025-08-08
- Publication Date
- 2026-06-30
AI Technical Summary
The conductive core of traditional cables is prone to breakage when repeatedly bent or subjected to mechanical stress. Pure copper conductive cores have low strength and are easily oxidized. The flexibility of copper alloy cables needs further optimization.
The copper alloy cable with a corrugated structure combines optimized copper alloy materials with the addition of tin, zinc and rare earth elements, reinforced with aramid fiber and a specific sheath material, and forms a conductive core through a rolling process.
It achieves a balance between the flexibility and strength of the conductive core, improves the tensile strength and corrosion resistance of the material, prevents the sheath layer from breaking, and generates a dense carbon layer during combustion to block oxygen and reduce the emission of toxic gases.
Smart Images
Figure CN224437211U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of cable technology, specifically to an optimized copper alloy cable with a corrugated conductive core. Background Technology
[0002] Traditional cables typically have a linear conductive core, which is prone to breakage and short circuits when subjected to repeated bending or mechanical stress. While some patents (such as CN101650991A) propose using a rolling process to create a corrugated conductive core to improve flexibility, this does not incorporate material optimization. Furthermore, while pure copper conductive cores offer excellent conductivity, they suffer from low strength and are prone to oxidation, and although copper alloy cables (such as CN119170156A) improve strength, their flexibility requires further optimization.
[0003] The present invention aims to provide a copper alloy cable with a corrugated conductive core, which solves the contradictions in flexibility, conductivity and durability of existing cables by combining structural design and material optimization. Utility Model Content
[0004] The purpose of this invention is to provide an optimized copper alloy cable with a corrugated conductive core, which solves the above-mentioned technical problems.
[0005] To achieve the above objectives, this utility model provides the following technical solution: a wave-shaped conductive core optimized copper alloy cable, comprising a conductive core composed of at least one copper alloy wire with a periodic wave-shaped structure, wherein the wavelength range of the wave-shaped structure is 2mm to 10mm, the amplitude range is 1mm to 5mm, and the chemical composition of the copper alloy wire by mass percentage includes: copper (Cu) 85%-95%, tin (Sn) 2%-5%, zinc (Zn) 1%-3%, and rare earth elements (at least one selected from lanthanum and cerium) 0.1%-0.5%;
[0006] The overall structure of the cable also includes:
[0007] A conductor layer formed by multiple wavy conductive cores arranged in parallel or twisted together;
[0008] An insulating layer covering the outside of the conductor layer, the insulating layer material being cross-linked polyethylene or polyvinyl chloride, with a thickness of 0.5 mm to 1.5 mm;
[0009] An extruded sheath layer is formed on the outside of the insulation layer. The sheath layer is made of flame-retardant polyvinyl chloride or low-smoke halogen-free material. Aramid fiber reinforcing ribs are uniformly embedded in the sheath layer along the cable axis. The diameter of the aramid fiber is 0.1 mm to 0.3 mm, and the spacing between adjacent fibers is 3 mm to 8 mm.
[0010] Preferably, the thickness of the insulating layer is 0.8 mm to 1.2 mm, and nano-sized alumina (Al2O3) filler is added to the insulating layer, with the filler accounting for 1% to 5% by mass, in order to improve the heat resistance of the insulating layer.
[0011] Preferably, the thickness of the sheath layer is 1.0 mm to 2.0 mm, and the outer surface of the sheath layer is provided with anti-slip textures extending along the axial direction, the depth of the anti-slip textures being 0.2 mm to 0.5 mm and the width being 0.5 mm to 1.0 mm.
[0012] Preferably, the cable further comprises a shielding layer, which is located between the conductor layer and the insulation layer. The shielding layer is an aluminum-plastic composite tape or a copper wire braided layer. The thickness of the aluminum-plastic composite tape is 0.05 mm to 0.1 mm, and the braiding density of the copper wire braided layer is ≥80%.
[0013] Preferably, the outer side of the shielding layer is further covered with a glass fiber tape wrapping layer, with a wrapping overlap rate of 20% to 40%, to prevent the shielding layer from loosening.
[0014] This invention provides an optimized copper alloy cable with a corrugated conductive core. It offers the following advantages:
[0015] (1) This utility model uses a wave-shaped structure to disperse bending stress through periodic deformation, avoiding the fracture caused by stress concentration in traditional straight conductive cores. The solid solution strengthening of tin and zinc in the copper alloy and the grain refinement strengthening effect of rare earth elements increase the tensile strength of the material to over 300 MPa (pure copper is about 200 MPa). At the same time, rare earth elements can purify the grain boundaries and improve corrosion resistance. The synergistic effect of the wave-shaped structure and the high-strength copper alloy achieves a balance between flexibility and strength.
[0016] (2) This utility model utilizes aramid fibers to achieve high modulus (100-200 GPa), high strength (3-4 GPa), and low density (1.44 g / cm³). 3 The axial embedding effectively disperses tensile stress, preventing sheath layer breakage. Flame retardants (such as aluminum hydroxide) in the sheath material decompose and absorb heat during combustion, generating a dense carbon layer to block oxygen; the low-smoke, halogen-free material also reduces toxic gas emissions. Anti-slip textures (depth 0.2mm to 0.5mm, width 0.5mm to 1.0mm) increase the coefficient of friction by increasing surface roughness, facilitating installation. Attached Figure Description
[0017] Figure 1 This is a schematic cross-sectional view of the cable structure of this utility model;
[0018] Figure 2 This is a schematic diagram of the conductive core structure of this utility model.
[0019] In the figure: conductive core 21, conductor layer 22, insulating layer 23, sheath layer 24, aramid fiber reinforcing rib 25, shielding layer 26, glass fiber tape wrapping layer 27. Detailed Implementation
[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0021] Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.
[0022] A preferred embodiment of the corrugated conductive core optimized copper alloy cable provided by this utility model is, for example... Figure 1-2 As shown: A copper alloy cable with a corrugated conductive core includes a conductive core 21 composed of at least one copper alloy wire with a periodic corrugated structure. The wavelength range of the corrugated structure is 2 mm to 10 mm, and the amplitude range is 1 mm to 5 mm. The chemical composition of the copper alloy wire by mass percentage includes: 85%-95% copper (Cu), 2%-5% tin (Sn), 1%-3% zinc (Zn), 0.1%-0.5% rare earth elements (selected from at least one of lanthanum and cerium), and the remainder being unavoidable impurities.
[0023] The overall structure of the cable includes:
[0024] A conductor layer 22 is formed by multiple wavy conductive cores 21 arranged in parallel or twisted together.
[0025] An insulating layer 23 is wrapped around the outside of the conductor layer 22. The insulating layer 23 is made of cross-linked polyethylene (XLPE) or polyvinyl chloride (PVC) and has a thickness of 0.5 mm to 1.5 mm.
[0026] The sheath layer 24 is extruded on the outside of the insulation layer 23. The material of the sheath layer 24 is flame-retardant polyvinyl chloride (PVC) or low smoke halogen-free (LSZH) material. Aramid fiber reinforcing ribs 25 are uniformly embedded in the sheath layer 24 along the cable axis. The diameter of the aramid fiber is 0.1 mm to 0.3 mm and the spacing between adjacent fibers is 3 mm to 8 mm.
[0027] The corrugated conductive core is formed through a rolling process, the specific steps of which include:
[0028] (1) The copper alloy rod is bundled into wire cores with a single wire diameter of 0.05 mm to 0.2 mm by a wire bundling machine;
[0029] (2) The bundled wire cores are twisted together into multi-strand wire cores using a re-twisting machine;
[0030] (3) The stranded wire core is fed into the rolling machine and rolled into a wave-shaped structure by the meshing gear mold (module of 0.5mm to 2mm). During the rolling process, the gap of the rolling machine is controlled to be 50%-80% of the wire core diameter, and the rolling speed is 5m / min to 20m / min.
[0031] The insulation layer 23 has a thickness of 0.8 mm to 1.2 mm, and nano-sized alumina (Al2O3) filler is added to the insulation layer 23, with the filler accounting for 1% to 5% by mass, in order to improve the heat resistance of the insulation layer 23.
[0032] The thickness of the sheath layer 24 is 1.0 mm to 2.0 mm, and the outer surface of the sheath layer 24 is provided with anti-slip textures extending along the axial direction, the depth of the anti-slip textures being 0.2 mm to 0.5 mm and the width being 0.5 mm to 1.0 mm;
[0033] The aramid fiber reinforcing rib 25 is embedded as follows: during the extrusion process of the sheath layer 24, the aramid fiber is simultaneously fed into the extruder die head through a pre-tension control device (tension range of 5N to 20N) so that the aramid fiber and the sheath layer 24 material are composite formed, and the embedding angle of the aramid fiber and the cable axis is 0° to 15°.
[0034] The cable has a rated voltage of 300V to 1000V, an applicable temperature range of -40℃ to 105℃, and meets the following performance indicators:
[0035] (1) DC resistance: ≤0.015Ω / m (at 20℃, conforms to GB / T 3956-2008 standard);
[0036] (2) Bending radius: ≤10 times the cable outer diameter, bending times ≥100,000 times without breakage;
[0037] (3) Corrosion resistance: After 72 hours of salt spray test (GB / T 2423.17-2008), there are no obvious corrosion marks on the surface;
[0038] (4) Flame retardant performance: The sheath layer reaches V-0 level (UL94 standard);
[0039] The cable is also provided with a shielding layer 26, which is located between the conductor layer 22 and the insulation layer 23. The shielding layer 26 is an aluminum-plastic composite tape or a copper wire braided layer. The thickness of the aluminum-plastic composite tape is 0.05mm to 0.1mm, and the braiding density of the copper wire braided layer is ≥80%.
[0040] The outer side of the shielding layer 26 is also covered with a fiberglass tape wrapping layer 27, with a wrapping overlap rate of 20% to 40%, to prevent the shielding layer from loosening.
[0041] In the rolling process, the tooth profile parameters of the gear mold are matched with the waveform parameters of the corrugated conductive core, and the tooth tip clearance of the gear mold is adjustable, ranging from 40% to 90% of the core diameter, to adapt to the rolling requirements of different wavelengths and amplitudes. After rolling, the waveform parameters of the corrugated conductive core are monitored in real time by an online detection device (such as a laser diameter gauge). If the wavelength or amplitude deviation is detected to exceed ±0.2mm, the gap or speed of the rolling machine is adjusted through the feedback control system.
[0042] The method for manufacturing cables includes the following steps:
[0043] (1) Prepare copper alloy rods and bundle and twist them into wire cores;
[0044] (2) The wire core is formed into a wavy conductive core by a rolling process;
[0045] (3) Twisting multiple wavy conductive cores together into a conductor layer;
[0046] (4) The conductor layer is wrapped with an insulating layer, a shielding layer (optional), and a sheath layer in sequence on the outside of the conductor layer;
[0047] (5) Conduct performance tests on the finished cables, including conductivity tests, bending tests, corrosion resistance tests and flame retardancy tests.
[0048] The well-known technical solutions and / or characteristics of the above-described schemes are not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solution of this utility model, and these should also be considered within the scope of protection of this utility model. These modifications will not affect the effectiveness of the implementation of this utility model or the practicality of the patent. The scope of protection claimed in this application shall be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.
[0049] Finally, it should be noted that the above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. 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 wave-shaped conductive core optimized copper alloy cable comprising a conductive core (21) made of at least one copper alloy wire in a periodic wave-shaped structure, characterized in that: The wavelength range of the wave-shaped structure is 2mm to 10mm, the amplitude range is 1mm to 5mm, and the chemical composition of the copper alloy wire by mass percentage includes: 85%-95% copper, 2%-5% tin, 1%-3% zinc, and 0.1%-0.5% rare earth elements. The overall structure of the cable also includes: A conductor layer (22) is formed by multiple wavy conductive cores (21) arranged in parallel or twisted together; An insulating layer (23) covering the outside of the conductor layer (22) is made of cross-linked polyethylene or polyvinyl chloride and has a thickness of 0.5 mm to 1.5 mm. A sheath layer (24) is extruded on the outside of the insulation layer (23). The material of the sheath layer (24) is flame-retardant polyvinyl chloride or low-smoke halogen-free material. Aramid fiber reinforcing ribs (25) are uniformly embedded in the sheath layer (24) along the cable axis. The diameter of the aramid fiber is 0.1 mm to 0.3 mm, and the spacing between adjacent fibers is 3 mm to 8 mm.
2. A wave-shaped conductive core optimized copper alloy cable as claimed in claim 1, characterized in that: The insulation layer (23) has a thickness of 0.8 mm to 1.2 mm, and nano-sized alumina filler is added to the insulation layer (23) with a filler mass ratio of 1% to 5% to improve the heat resistance of the insulation layer (23).
3. A wave-shaped conductive core optimized copper alloy cable as claimed in claim 1, wherein: The thickness of the sheath layer (24) is 1.0 mm to 2.0 mm, and the outer surface of the sheath layer (24) is provided with anti-slip texture extending along the axial direction, the depth of the anti-slip texture is 0.2 mm to 0.5 mm, and the width is 0.5 mm to 1.0 mm.
4. A wave-shaped conductive core optimized copper alloy cable as claimed in claim 1, wherein: The cable is also provided with a shielding layer (26), which is located between the conductor layer (22) and the insulation layer (23). The shielding layer (26) is an aluminum-plastic composite tape or a copper wire braided layer. The thickness of the aluminum-plastic composite tape is 0.05 mm to 0.1 mm, and the braiding density of the copper wire braided layer is ≥80%.
5. A wave-shaped conductive core optimized copper alloy cable as claimed in claim 4, characterized in that: The outer side of the shielding layer (26) is also covered with a glass fiber tape wrapping layer (27), with a wrapping overlap rate of 20% to 40%, to prevent the shielding layer from loosening.