An energy storage cable with good flexibility

Abstract

This utility model discloses an energy storage cable with good flexibility, including a copper core, an insulating buffer layer, an elastic support layer, a braided shielding layer, and a protective layer, arranged sequentially from the inside to the outside. The insulating buffer layer wraps around the copper core, and an isolation layer is provided between the insulating buffer layer and the copper core. The elastic support layer has elastic sleeves on both the inner and outer sides, and multiple evenly arranged elastic sheets are provided between the elastic sleeves on both sides. The braided shielding layer is composed of multiple spiral tubes arranged around the elastic sleeves. This utility model forms a multi-layer buffer structure through the elastic support layer and the evenly arranged elastic sheets in combination with the inner and outer elastic sleeves. The arc-shaped groove design disperses stress along the arc surface during bending, avoiding localized stress concentration. The braided shielding layer adopts a multi-spiral tube arrangement structure, which maintains the continuity of the metal shielding and is compatible with the bending action of the cable through the spiral shape, solving the problem of easy breakage when bending traditional straight-wound shielding layers.

Description

Technical Field

[0001] This utility model specifically relates to an energy storage cable with good flexibility. Background Technology

[0002] Energy storage technology, as a key support for achieving energy transition and grid stability, has developed rapidly in recent years and is widely used in new energy vehicles, renewable energy grid connection, industrial backup power, data centers, portable devices, and home energy storage systems. As the "energy transmission artery" connecting energy storage battery packs with power conversion systems, loads, or the power grid, the performance of energy storage cables is crucial, directly affecting the efficiency, safety, and reliability of the entire energy storage system.

[0003] In many energy storage applications, especially in fixed energy storage cabinets that require frequent plugging and unplugging or are installed in confined spaces, cables not only need to carry large currents but also often face harsh mechanical stress environments such as repeated bending, torsion, vibration, and space constraints. Traditional energy storage cables typically have large conductor cross-sectional areas to meet high current carrying requirements. Traditional designs often use single solid conductors with large diameters or multiple stranded conductors with large pitch and rigid structures. These conductors are prone to metal fatigue, strand breakage, or even fracture when repeatedly bent or bent at small radii, leading to increased resistance and overheating. In severe cases, this can cause connection failures, fires, and other safety accidents. Some cables use insulation or sheath materials with high hardness and poor elastic recovery to improve mechanical strength or weather resistance. These materials are prone to permanent deformation, cracking, or whitening after small-radius bending or repeated bending, losing their insulation and protective functions and reducing cable lifespan.

[0004] Therefore, it is necessary to invent an energy storage cable with good flexibility to solve the above problems. Utility Model Content

[0005] (a) Purpose of the utility model

[0006] To address the technical problems existing in the background art, this utility model proposes an energy storage cable with good flexibility.

[0007] (II) Technical Solution

[0008] To achieve the above objectives, this utility model provides the following technical solution: an energy storage cable with good flexibility, comprising a copper core, and further comprising an insulating buffer layer, an elastic support layer, a braided shielding layer and a protective layer arranged sequentially from the inside out;

[0009] The insulating buffer layer is wrapped around the outside of the copper core, and an isolation layer is provided between the insulating buffer layer and the copper core. The elastic support layer is wrapped around the outside of the insulating buffer layer, and the braided shielding layer is fixed inside the protective layer.

[0010] The elastic support layer is provided with elastic sleeves on both the inner and outer sides, and a number of evenly arranged elastic sheets are provided between the elastic sleeves on both sides.

[0011] The braided shielding layer is composed of multiple spiral tubes arranged together, which are wrapped around the outside of the elastic sleeve.

[0012] Preferably, the copper core is further provided with a conductor shielding layer, and a filler is provided between the isolation layer and the copper core. The insulating buffer layer is fixed to the outside of the isolation layer and includes two inner insulating layers and an outer buffer layer.

[0013] Preferably, the elastic sleeve on both the inner and outer sides of the elastic support layer is provided with a plurality of arc-shaped grooves, the plurality of arc-shaped grooves are concentrically arranged on the outer wall of the elastic sleeve, the two ends of the plurality of arc-shaped grooves support the inner and outer insulating buffer layers and the braided shielding layer, and the plurality of elastic sheets are concentrically arranged on both the inner and outer sides of the elastic sleeve.

[0014] Preferably, a flexible area is provided between the inner and outer elastic sleeves, and a plurality of slots matching the elastic sheet are provided in the flexible area.

[0015] Preferably, the outer wall of the protective layer has an annular trough, and the woven shielding layer is spirally arranged on the inner wall of the protective layer.

[0016] Compared with the prior art, the beneficial effects of the above-mentioned technical solution of this utility model are:

[0017] This invention utilizes an elastic support layer to form a multi-layer buffer structure through inner and outer elastic sleeves and uniformly arranged elastic sheets. The arc-shaped groove design disperses stress along the arc surface during bending, avoiding localized stress concentration. The slot in the flexible area provides expansion and contraction space for the elastic sheets, and together with the spirally arranged braided shielding layer, it can adapt to repeated bending in confined spaces.

[0018] This utility model's braided shielding layer adopts a multi-spiral tube arrangement structure, which maintains the continuity of the metal shielding and is compatible with cable bending movements through the spiral shape, solving the problem of easy breakage when the traditional straight-wound shielding layer is bent; at the same time, the conductor shielding layer and the spiral shielding layer form a double shield, which is suitable for high and low voltage signal coexistence environments in energy storage systems. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this utility model. For those skilled in the art, other drawings can be obtained based on these drawings.

[0020] Figure 1This is a schematic diagram of the overall structure of this utility model;

[0021] Figure 2 This is a schematic diagram showing the disassembled structure of each layer of this utility model;

[0022] Figure 3 This is a schematic diagram of the disassembled protective layer structure of this utility model;

[0023] Figure 4 This is a schematic diagram of the elastic support layer structure of this utility model.

[0024] Explanation of reference numerals in the attached figures:

[0025] 1. Copper core; 11. Conductor shielding layer; 2. Insulating buffer layer; 21. Insulating layer; 22. Buffer layer; 3. Elastic support layer; 31. Elastic sleeve; 32. Elastic sheet; 33. Arc groove; 34. Flexible area; 35. Mounting slot; 4. Braided shielding layer; 41. Spiral tube; 5. Protective layer; 51. Annular trough; 6. Isolation layer; 7. Filler. Detailed Implementation

[0026] To enable those skilled in the art to better understand the technical solution of this utility model, the present utility model will be further described in detail below with reference to the accompanying drawings.

[0027] This utility model provides, for example Figure 1-4 The energy storage cable shown includes a copper core 1, and also includes an insulating buffer layer 2, an elastic support layer 3, a braided shielding layer 4 and a protective layer 5 arranged sequentially from the inside to the outside.

[0028] Specifically, the insulating buffer layer 2 is wrapped around the outside of the copper core 1, and an isolation layer 6 is provided between the insulating buffer layer 2 and the copper core 1. The elastic support layer 3 is wrapped around the outside of the insulating buffer layer 2, and the braided shielding layer 4 is fixed inside the protective layer 5.

[0029] Specifically, the elastic support layer 3 is provided with elastic sleeves 31 on both the inner and outer sides, and a number of evenly arranged elastic sheets 32 are provided between the elastic sleeves 31 on both sides.

[0030] Specifically, the braided shielding layer 4 is composed of multiple spiral tubes 41 arranged together, which are wrapped around the elastic sleeve 31.

[0031] In this embodiment, the two inner insulating layers 21 are both cross-linked polyethylene, each with a thickness of 0.5 mm, and are produced using a step-by-step extrusion process; the outer buffer layer 22 is foamed EPDM rubber, which is molded and bonded to the outside of the insulating layer 21.

[0032] Reference Figure 2The copper core 1 is also provided with a conductor shielding layer 11. A filler 7 is provided between the isolation layer 6 and the copper core 1. An insulating buffer layer 2 is fixed to the outside of the isolation layer 6, including two inner insulating layers 21 and an outer buffer layer 22.

[0033] In this embodiment, the copper core 1 is made of 7 strands of annealed soft copper wire with a diameter of 0.5 mm, with the outer layer twisted in a right-hand direction; the conductor shielding layer 11 is made of semi-conductive butyl rubber with a thickness of 0.2 mm, extruded onto the outer surface of the copper core. The filler 7 is a flame-retardant glass fiber rope, which fills the gap between the copper core 1 and the insulating layer 6, making the cross-section circular; the insulating layer 6 is made of polyimide film, wrapped around the outside of the filler 7.

[0034] Reference Figure 4 Multiple arc-shaped grooves 33 are provided on the inner and outer sides of the elastic sleeve 31 of the elastic support layer 3. The multiple arc-shaped grooves 33 are concentrically arranged on the outer wall of the elastic sleeve 31. The two ends of the multiple arc-shaped grooves 33 support the inner and outer insulating buffer layers 2 and the braided shielding layer 4. Multiple elastic sheets 32 are concentrically arranged on the inner and outer sides of the elastic sleeve 31.

[0035] Specifically, a flexible area 34 is provided between the inner and outer elastic sleeves 3, and multiple slots 35 for matching elastic pieces 32 are provided in the flexible area 34.

[0036] In this embodiment, the elastic sleeve 31 is injection molded from thermoplastic elastomer, and the thickness of both the inner and outer sleeves is 0.3mm; the elastic sheet 32 ​​is made of beryllium bronze, with a thickness of 0.15mm and a width of 2mm, and is curved; the arc groove 33 has a depth of 0.2mm and an arc length of 5mm, and is concentrically arranged on the outer wall of the sleeve; the flexible area 34 has a width of 3mm, and the mounting slot 35 has a depth of 0.2mm, and is interference-fitted with the elastic sheet 32.

[0037] Reference Figure 3 The outer wall of the protective layer 5 is provided with annular troughs 51, and the woven shielding layer 4 is spirally arranged on the inner wall of the protective layer 5.

[0038] In this embodiment, the protective layer 5 is made of oil-resistant polyurethane by extrusion molding and has a thickness of 1.2 mm; the outer wall annular trough 51 has a depth of 0.3 mm and a pitch of 8 mm.

[0039] In this embodiment, the copper core stranding is achieved by stranding 7 copper wires through a tubular stranding machine, simultaneously extruding the conductor shielding layer 11; then, glass fiber rope is wrapped around the copper core for filling, followed by wrapping the polyimide insulating layer 6.

[0040] Specifically, the inner insulating layer 21 is first extruded, then the outer insulating layer 21 is extruded after cooling, and finally the foamed buffer layer 22 is molded.

[0041] Specifically, the elastic sheet 32 ​​is inserted into the slot 35 of the flexible area 34, and the inner and outer elastic sleeves 31 and the elastic sheet 32 ​​are integrally formed by injection molding to ensure that the arc groove 33 is concentrically aligned.

[0042] Specifically, the spiral tube 41 is spirally wound around the outer circumference of the elastic sleeve 31, and PUR material is wrapped around the outside of the spiral tube through an extruder, while annular troughs 51 are simultaneously extruded and cooled for shaping.

[0043] In this embodiment, the annular trough 51 of the protective layer 5 increases the friction during construction, allowing a single person to drag the cable through the narrow passage of the energy storage cabinet; the flexible area 34 of the elastic support layer 3 allows the cable to maintain structural stability when twisted, adapting to the vibration environment of the energy storage equipment.

[0044] The foregoing description only illustrates certain exemplary embodiments of the present invention. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. An energy storage cable with good flexibility, comprising a copper core (1), characterized in that: It also includes an insulating buffer layer (2), an elastic support layer (3), a braided shielding layer (4), and a protective layer (5) arranged sequentially from the inside out; The insulating buffer layer (2) is wrapped around the copper core (1), and an isolation layer (6) is provided between the insulating buffer layer (2) and the copper core (1). The elastic support layer (3) is wrapped around the insulating buffer layer (2), and the braided shielding layer (4) is fixed inside the protective layer (5). The elastic support layer (3) is provided with elastic sleeves (31) on both the inner and outer sides, and a plurality of evenly arranged elastic sheets (32) are provided between the elastic sleeves (31) on both sides. The braided shielding layer (4) is composed of multiple spiral tubes (41) arranged together, and the multiple spiral tubes (41) are wrapped around the outside of the elastic sleeve (31).

2. The energy storage cable with good flexibility according to claim 1, characterized in that: The copper core (1) is further provided with a conductor shielding layer (11) on the outside, and a filler (7) is provided between the isolation layer (6) and the copper core (1). The insulating buffer layer (2) is fixed to the outside of the isolation layer (6) and includes two inner insulating layers (21) and an outer buffer layer (22).

3. The energy storage cable with good flexibility according to claim 1, characterized in that: Multiple arc-shaped grooves (33) are provided on the inner and outer sides of the elastic sleeve (31) of the elastic support layer (3). The multiple arc-shaped grooves (33) are concentrically arranged on the outer wall of the elastic sleeve (31). The two ends of the multiple arc-shaped grooves (33) support the inner and outer insulating buffer layer (2) and the braided shielding layer (4). Multiple elastic sheets (32) are concentrically arranged on the inner and outer sides of the elastic sleeve (31).

4. The energy storage cable with good flexibility according to claim 3, characterized in that: A flexible area (34) is provided between the inner and outer elastic sleeves (31), and a plurality of slots (35) matching the elastic sheet (32) are provided in the flexible area (34).

5. The energy storage cable with good flexibility according to claim 1, characterized in that: The outer wall of the protective layer (5) is provided with annular troughs (51), and the woven shielding layer (4) is spirally arranged on the inner wall of the protective layer (5).

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