A low-smoke halogen-free flat cable resistant to high temperature and humidity aging

Abstract

This utility model discloses a low-smoke halogen-free flat cable resistant to high temperature and humidity aging, relating to the field of cable technology. It includes a conductor layer, an insulation layer, a filler layer, an inner sheath layer, a shielding layer, a tensile reinforcement layer, an outer sheath layer, and a moisture-proof layer. Through a multi-layered structural design, this utility model forms a complete protective system, effectively improving the cable's resistance to high temperature and humidity aging. The conductor layer uses multi-strand copper wires tightly twisted together, improving the conductor's conductivity and mechanical strength, reducing the skin effect, and lowering resistance loss. The insulation layer is made of low-smoke halogen-free, high-temperature resistant insulating material, covering the outside of the conductor layer. It not only has excellent insulation performance but also maintains stable physical and chemical properties under high-temperature environments, preventing softening and deformation. Furthermore, it produces low smoke and halogen-free combustion, making it environmentally friendly and safe. The filler layer is located in a groove outside the insulation layer, filling the gaps around the flat conductor layer and improving the cable's overall stability and resistance to deformation.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, and in particular to a low-smoke halogen-free flat cable that is resistant to high temperature and high humidity aging. Background Technology

[0002] In industrial production, energy transmission, and other fields, the operating environment of cables is becoming increasingly complex. Traditional cables, especially under high temperature and humidity conditions, present numerous problems. Currently, flat cables on the market have significant shortcomings in their resistance to high temperature and humidity aging: the insulation layer is prone to softening and deformation under high temperature conditions, leading to a decline in insulation performance; in high humidity environments, moisture easily penetrates the cable's interior, affecting its service life and safety; and combustion produces large amounts of smoke and toxic halides, posing hazards to personnel safety and the environment.

[0003] Therefore, it is necessary to invent a low-smoke halogen-free flat cable that is resistant to high temperature and high humidity aging to solve the above problems. Utility Model Content

[0004] The purpose of this invention is to address the significant shortcomings of existing flat cables in terms of resistance to high temperature and high humidity aging, and to provide a low-smoke halogen-free flat cable that is resistant to high temperature and high humidity aging.

[0005] To achieve the above objectives, this utility model adopts the following technical solution: a low-smoke halogen-free flat cable resistant to high temperature and humidity aging, comprising a conductor layer, an insulation layer, a filling layer, an inner sheath layer, a shielding layer, a tensile reinforcement layer, an outer sheath layer, and a moisture-proof layer. The conductor layer is formed by stranding multiple copper wires. The insulation layer covers the outside of the conductor layer and is made of low-smoke halogen-free high-temperature resistant insulation material. The filling layer is disposed in a groove on the outside of the insulation layer to fill the gaps around the flat conductor layer. The inner sheath layer covers the outside of the insulation layer and the filling layer and is made of low-smoke halogen-free flame-retardant material. The shielding layer covers the outside of the inner sheath layer and is woven from tin-plated copper wire. The tensile reinforcement layer covers the outside of the shielding layer and is woven from aramid fiber. The outer sheath layer covers the outside of the tensile reinforcement layer and is made of low-smoke halogen-free weather-resistant material. The moisture-proof layer is disposed between the outer sheath layer and the tensile reinforcement layer and is wrapped with semi-conductive water-resistant tape.

[0006] As a further description of the above technical solution: the multi-strand copper wires of the conductor layer are tightly twisted, the twisting direction is to the right and the twisting pitch is 10-15 times the conductor diameter.

[0007] As a further description of the above technical solution: the thickness of the insulating layer is 0.8-1.2mm, it is coated on the outside of the conductor layer by co-extrusion process, and the cross-section of the insulating layer is rectangular to match the flat shape of the conductor layer.

[0008] As a further description of the above technical solution: the filling layer is made of low-smoke, halogen-free, flame-retardant glass fiber rope, which is filled in the four corner grooves on the outside of the insulation layer, with a filling density of not less than 85%.

[0009] As a further description of the above technical solution: the thickness of the inner sheath layer is 1.0-1.5mm, and it is wrapped on the outside of the insulation layer and the filling layer by extrusion process, and a layer of mica tape treated with silane coupling agent is provided between the inner sheath layer and the insulation layer.

[0010] As a further description of the above technical solution: the braiding density of the shielding layer is not less than 90%, the diameter of the tinned copper wire is 0.15-0.2mm and the braiding angle is 45°-55°.

[0011] As a further description of the above technical solution: the tensile reinforcing layer has two aramid fiber braided layers, the two layers are braided in opposite directions and the braiding density is not less than 80%.

[0012] As a further description of the above technical solution: the overlap rate of the semi-conductive resistive water tape wrapped in the moisture-proof layer is not less than 25%, the wrapping direction is to the left, and the thickness of the semi-conductive resistive water tape is 0.3-0.5mm.

[0013] In summary, due to the adoption of the above technical solution, the beneficial effects of this utility model are:

[0014] This utility model, through a multi-layered structural design comprising a conductor layer, an insulation layer, a filler layer, an inner sheath layer, a shielding layer, a tensile reinforcement layer, an outer sheath layer, and a moisture-proof layer, forms a complete protective system, effectively improving the cable's resistance to high-temperature and high-humidity aging. The conductor layer uses multi-strand copper wires tightly twisted together, improving the conductor's conductivity and mechanical strength, reducing the skin effect, and lowering resistance loss. The insulation layer, made of low-smoke halogen-free, high-temperature resistant insulating material, covers the outside of the conductor layer, providing not only excellent insulation performance but also maintaining stable physical and chemical properties under high-temperature environments, preventing softening and deformation. Furthermore, it produces low-smoke, halogen-free combustion, making it environmentally friendly and safe. The filler layer, located in a groove on the outside of the insulation layer, fills the gaps around the flat conductor layer, making the cable structure more compact and improving the cable's overall stability and resistance to deformation. The inner sheath layer, made of low-smoke halogen-free flame-retardant material, covers the outside of the insulation and filler layers, further enhancing the cable's flame-retardant and insulation performance. Simultaneously, the mica tape between the inner sheath and the insulation layer improves high-temperature resistance.

[0015] The inner sheath of this invention is made of low-smoke halogen-free flame-retardant material and covers the outside of the insulation and filler layers, further enhancing the flame-retardant and insulation properties of the cable. Simultaneously, the mica tape between the inner sheath and the insulation layer improves high-temperature resistance. The shielding layer, woven from tin-plated copper wire, covers the outside of the inner sheath and provides excellent electromagnetic shielding performance, effectively reducing the impact of external electromagnetic interference on cable signal transmission. It also prevents electromagnetic radiation generated by the cable itself from interfering with surrounding equipment. The tensile reinforcement layer, woven from aramid fiber, covers the outside of the shielding layer and possesses extremely high tensile strength and tear resistance, capable of withstanding significant tensile and mechanical stresses. This prevents cable damage due to stretching during use and extends the cable's service life. The moisture-proof layer, located between the outer sheath and the tensile reinforcement layer, is made of semi-conductive water-resistant tape and effectively prevents moisture from penetrating the cable, improving its reliability in high-humidity environments and avoiding problems such as decreased insulation performance and short circuits caused by moisture intrusion. Attached Figure Description

[0016] Figure 1 A schematic diagram of the cross-sectional structure of a flat cable according to an embodiment of the present invention is shown;

[0017] Figure 2 A schematic diagram of a groove structure provided according to an embodiment of the present invention is shown.

[0018] Legend:

[0019] 1. Conductor layer; 2. Insulating layer; 3. Groove; 4. Filler layer; 5. Mica tape; 6. Inner sheath layer; 7. Shielding layer; 8. Tensile reinforcement layer; 9. Moisture-proof layer; 10. Outer sheath layer. 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 skilled in the art without creative effort are within the protection scope of the present utility model.

[0021] Please see Figure 1 and Figure 2 The present invention provides a technical solution: a low-smoke halogen-free flat cable resistant to high temperature and high humidity aging, comprising a conductor layer 1, an insulation layer 2, a filling layer 4, an inner sheath layer 6, a shielding layer 7, a tensile strengthening layer 8, an outer sheath layer 10, and a moisture-proof layer 9.

[0022] Specifically, such as Figures 1-2As shown, conductor layer 1 is composed of multiple strands of copper wire twisted together, forming a flat shape. The multiple strands of copper wire in conductor layer 1 are tightly twisted, with the twisting direction to the right and the twisting pitch being 10-15 times the conductor diameter. Insulation layer 2 covers the outside of conductor layer 1 and is made of low-smoke halogen-free, high-temperature resistant insulating material. The thickness of insulation layer 2 is 0.8-1.2mm. It is wrapped around the outside of conductor layer 1 using a co-extrusion process, and the cross-section of insulation layer 2 is rectangular to match the flat shape of conductor layer 1. Filler layer 4 is placed in the groove 3 on the outside of insulation layer 2 to fill the gaps around the flat conductor layer 1. Filler layer 4 is made of low-smoke halogen-free, flame-retardant fiberglass rope and fills the four corner grooves 3 on the outside of insulation layer 2 with a filling density of not less than 85%. Inner sheath layer 6 covers the outside of insulation layer 2 and filler layer 4 and is made of low-smoke halogen-free, flame-retardant material. The thickness of inner sheath layer 6 is 1.0-1.5mm and is wrapped using an extrusion process. A layer of mica tape 5 treated with silane coupling agent is disposed outside the insulation layer 2 and the filler layer 4, and between the inner sheath layer 6 and the insulation layer 2. A shielding layer 7 covers the outside of the inner sheath layer 6 and is woven from tin-plated copper wire. The weaving density of the shielding layer 7 is not less than 90%, the diameter of the tin-plated copper wire is 0.15-0.2 mm, and the weaving angle is 45°-55°. A tensile reinforcing layer 8 covers the outside of the shielding layer 7 and is woven from aramid fiber. The aramid fiber braided layer consists of two layers, with opposite braiding directions and a braiding density of not less than 80%. The outer sheath layer 10 covers the outside of the tensile reinforcement layer 8 and is made of low-smoke, halogen-free, and weather-resistant material. The moisture-proof layer 9 is located between the outer sheath layer 10 and the tensile reinforcement layer 8 and is formed by wrapping semi-conductive water-resistant tape. The overlap rate of the semi-conductive water-resistant tape wrapping in the moisture-proof layer 9 is not less than 25%, the wrapping direction is to the left, and the thickness of the semi-conductive water-resistant tape is 0.3-0.5 mm.

[0023] Therefore, in the actual manufacturing process, firstly, multiple strands of copper wire are twisted in a right-hand direction, with the twisting pitch controlled at 10-15 times the conductor diameter, forming a flat conductor layer 1. Then, a low-smoke halogen-free, high-temperature resistant insulating material is coated onto the outside of the conductor layer 1 using a co-extrusion process, forming a rectangular insulating layer 2 with a thickness of 0.8-1.2 mm. Next, low-smoke halogen-free, flame-retardant glass fiber rope is filled into the four corner grooves 3 on the outside of the insulating layer 2, with a filling density of not less than 85%, to fill the gaps. Then, an inner sheath layer 6 with a thickness of 1.0-1.5 mm is wrapped onto the outside of the insulating layer 2 and the filling layer 4 using an extrusion process, and a layer of mica tape 5 treated with silane coupling agent is wrapped between the inner sheath layer 6 and the insulating layer 2. Finally, a tin-plated copper wire shielding layer 7 is braided on the outside of the inner sheath layer 6, with a braiding density of not less than 90%, the tin-plated copper wire diameter being 0.15-0.2 mm, and the braiding angle being 45°-55°. Two layers of aramid fiber tensile reinforcement layer 8 are woven outside the shielding layer 7, with opposite weaving directions and a weaving density of not less than 80%. A semi-conductive resistive water-resistant tape is wrapped between the outer sheath layer 10 and the tensile reinforcement layer 8 as a moisture-proof layer 9, with an overlap rate of not less than 25%, a left-hand wrapping direction, and a thickness of 0.3-0.5 mm. Finally, an outer sheath layer 10 made of low-smoke halogen-free weather-resistant material is extruded outside the tensile reinforcement layer 8, completing the cable manufacturing process.

[0024] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A low-smoke halogen-free flat cable resistant to high temperature and high humidity aging, characterized in that: The structure includes a conductor layer (1), an insulation layer (2), a filler layer (4), an inner sheath layer (6), a shielding layer (7), a tensile reinforcement layer (8), an outer sheath layer (10), and a moisture-proof layer (9). The conductor layer (1) is made of multiple strands of copper wire twisted together. The insulation layer (2) covers the outside of the conductor layer (1) and is made of low-smoke, halogen-free, high-temperature resistant insulating material. The filler layer (4) is located in the groove (3) on the outside of the insulation layer (2) and is used to fill the gaps around the flat conductor layer (1). The inner sheath layer (6) covers the conductor layer (1). The outer side of the insulation layer (2) and the filling layer (4) is made of low smoke halogen-free flame retardant material. The shielding layer (7) is wrapped around the outer side of the inner sheath layer (6) and is woven from tin-plated copper wire. The tensile reinforcing layer (8) is wrapped around the outer side of the shielding layer (7) and is woven from aramid fiber. The outer sheath layer (10) is wrapped around the outer side of the tensile reinforcing layer (8) and is made of low smoke halogen-free weather-resistant material. The moisture-proof layer (9) is set between the outer sheath layer (10) and the tensile reinforcing layer (8) and is wrapped with semi-conductive resistive water tape.

2. The low-smoke halogen-free flat cable resistant to high temperature and high humidity aging according to claim 1, characterized in that: The multi-strand copper wires of the conductor layer (1) are tightly twisted together, with the twisting direction being to the right and the twisting pitch being 10-15 times the conductor diameter.

3. The low-smoke halogen-free flat cable resistant to high temperature and high humidity aging according to claim 2, characterized in that: The insulation layer (2) has a thickness of 0.8-1.2 mm and is coated on the outside of the conductor layer (1) using a co-extrusion process. The cross-section of the insulation layer (2) is rectangular and matches the flat shape of the conductor layer (1).

4. The low-smoke halogen-free flat cable resistant to high temperature and high humidity aging according to claim 3, characterized in that: The filling layer (4) is made of low-smoke, halogen-free, flame-retardant glass fiber rope, which is filled in the four corner grooves (3) on the outside of the insulation layer (2), with a filling density of not less than 85%.

5. A low-smoke halogen-free flat cable resistant to high temperature and high humidity aging according to claim 4, characterized in that: The inner sheath layer (6) has a thickness of 1.0-1.5 mm and is wrapped on the outside of the insulation layer (2) and the filling layer (4) by extrusion process. A layer of mica tape (5) treated with silane coupling agent is provided between the inner sheath layer (6) and the insulation layer (2).

6. A low-smoke halogen-free flat cable resistant to high temperature and high humidity aging according to claim 5, characterized in that: The braiding density of the shielding layer (7) is not less than 90%, and the diameter of the tin-plated copper wire is 0.15-0.2mm and the braiding angle is 45°-55°.

7. A low-smoke halogen-free flat cable resistant to high temperature and high humidity aging according to claim 6, characterized in that: The tensile reinforcing layer (8) has two aramid fiber braided layers, with the two layers braided in opposite directions and with a braiding density of not less than 80%.

8. A low-smoke halogen-free flat cable resistant to high temperature and high humidity aging according to claim 7, characterized in that: The overlap rate of the semiconducting resistive water tape wrapping of the moisture-proof layer (9) is not less than 25%, the wrapping direction is to the left, and the thickness of the semiconducting resistive water tape is 0.3-0.5mm.

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