A high-current flexible busbar cable
By introducing a heat-conducting layer and a braided fiber sheath structure into the high-current flexible busbar cable, the problems of heat accumulation and flexibility are solved, achieving uniform heat dissipation and insulation protection, thus extending the cable's service life.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- NANYANG CABLE GRP
- Filing Date
- 2025-07-28
- Publication Date
- 2026-07-03
AI Technical Summary
High-current flexible busbar cables are prone to heat accumulation during use, leading to temperature rise, which affects current carrying capacity. In addition, their poor flexibility makes them susceptible to insulation layer cracking due to stress concentration.
The conductive foil sheet is wrapped with an insulating sleeve on the outside and a buffer layer and a heat-conducting layer on the inside, including a heat dissipation sleeve and a heat-conducting grease layer. The outer side has a woven fiber sleeve and a rubber strip. It uses ceramic heat-conducting particles for heat conduction and dissipation. The woven fiber sleeve is made of a mixture of aramid fiber and carbon fiber to improve flexibility.
It effectively dissipates heat, stabilizes temperature changes, prevents insulation layer cracking, extends cable service life, and improves bending performance.
Smart Images
Figure CN224457674U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of cable technology, specifically to a high-current flexible busbar cable. Background Technology
[0002] Flexible busbar cables, also known as insulated flexible busbars or laminated insulated flexible busbars, are power transmission components made by stacking multiple layers of flat, thin copper conductors that are corona-resistant. The outside of the cable is covered with an insulation layer through extrusion. It has many distinctive features and is widely used in many fields.
[0003] The high-current flexible busbar cable currently in use tends to generate heat during operation. Much of this heat cannot be effectively dissipated to the external environment, resulting in a higher temperature rise for the cable at the same current. This affects the cable's current-carrying capacity and is detrimental to its subsequent use. At the same time, the busbar cable exhibits poor flexibility, so frequent bending can easily cause insulation layer cracking due to internal stress concentration, thus affecting the cable's service life.
[0004] In summary, this utility model solves the problems in the background art by designing a high-current flexible busbar cable. Utility Model Content
[0005] The purpose of this invention is to provide a high-current flexible busbar cable to solve the problems mentioned in the background art.
[0006] To achieve the above objectives, this utility model provides the following technical solution:
[0007] A high-current flexible busbar cable includes a conductive foil and a sheath layer. The conductive foil is covered with an insulating sleeve, a buffer layer is provided between the insulating sleeve and the conductive foil, a heat-conducting layer is provided on the outside of the insulating sleeve, a braided fiber sleeve is provided on the inside of the sheath layer, and a rubber strip is provided inside the braided fiber sleeve.
[0008] The thermally conductive layer includes a heat dissipation sleeve and a thermally conductive grease layer. The heat dissipation sleeve is fixedly attached to the inner surface of the woven fiber sleeve, and the thermally conductive grease layer is fixedly covered to the outer surface of the insulating sleeve.
[0009] Furthermore, the interior of the heat dissipation sleeve is filled with ceramic thermally conductive particles, and the outer surface of the thermally conductive grease layer is integrally formed with the inner wall of the heat dissipation sleeve.
[0010] Through the above technical solution, the thermal grease layer can absorb the heat generated by the conductive foil, while the ceramic thermally conductive particles inside the heat dissipation sleeve can quickly guide the heat absorbed by the thermal grease layer and dissipate the heat to the external environment.
[0011] Furthermore, the insulating sleeve is made of a flexible polymer film;
[0012] The above technical solution can improve the insulation performance of the insulating sleeve by incorporating a flexible polymer film.
[0013] Furthermore, the rubber strips are embedded inside the woven fiber sleeve, and the rubber strips are distributed in an array about the inner wall of the woven fiber sleeve. The woven fiber sleeve is made of aramid fiber and carbon fiber mixed together, and the weaving density is 80-120 mesh.
[0014] The above technical solution, combining rubber strips and braided fiber sheaths, can improve the bending performance of cables.
[0015] Furthermore, the vertical cross-sectional shape of the rubber strip is circular;
[0016] Through the above technical solution, the circular shape of the rubber strip can come into contact with the woven fiber sleeve.
[0017] Furthermore, the buffer layer is a porous fluoropolymer film, and the thickness of the buffer layer is 0.05–0.2 mm.
[0018] Compared with the prior art, the beneficial effects of this utility model are:
[0019] 1. In this utility model, by setting a high-current flexible busbar cable, the heat-conducting layer structure design, in conjunction with the heat dissipation sheath and the heat-conducting grease layer, can uniformly absorb and guide the heat generated by the conductive foil, stabilize the temperature change of the cable when carrying current, and benefit subsequent use.
[0020] 2. In this utility model, a high-current flexible busbar cable is designed with braided fiber sheath and rubber strip. The combination of rubber strip and braided fiber sheath can absorb and disperse the concentrated stress of the cable, effectively preventing the insulation layer from cracking due to bending and ensuring the service life of the cable. Attached Figure Description
[0021] Figure 1 This is a schematic diagram of the overall structure of this utility model;
[0022] Figure 2 This is a schematic diagram of the structure of the conductive foil of this utility model;
[0023] Figure 3 For the present utility model Figure 2 Enlarged structural diagram of point A in the middle;
[0024] Figure 4 This is a schematic diagram of the structure of the rubber strip of this utility model.
[0025] In the diagram: 1. Conductive foil; 2. Sheath layer; 3. Insulating sleeve; 4. Buffer layer; 5. Thermal conductive layer; 501. Heat dissipation sheath; 502. Thermal grease layer; 6. Braided fiber sleeve; 601. Rubber strip. Detailed Implementation
[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the protection scope of the present utility model.
[0027] To facilitate understanding of this utility model, a more comprehensive description of the utility model will be given below with reference to the accompanying drawings, and several embodiments of the utility model will be provided. However, the utility model can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the utility model more thorough and complete.
[0028] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.
[0029] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.
[0030] For examples, please refer to Figure 1-4 This utility model provides a technical solution:
[0031] A high-current flexible busbar cable includes a conductive foil 1 and a sheath layer 2. The conductive foil 1 is covered with an insulating sleeve 3. A buffer layer 4 is provided between the insulating sleeve 3 and the conductive foil 1. A heat-conducting layer 5 is provided on the outside of the insulating sleeve 3. A braided fiber sleeve 6 is provided on the inside of the sheath layer 2. A rubber strip 601 is provided inside the braided fiber sleeve 6.
[0032] Specifically, the insulating sleeve 3 is made of a flexible polymer film, the buffer layer 4 is a porous fluoropolymer film, and the thickness of the buffer layer 4 is 0.05–0.2 mm.
[0033] In this embodiment, the insulating sleeve 3, which is made of a flexible polymer film, has good insulation performance, and the buffer layer 4 can facilitate the insulating sleeve 3 to wrap and protect the conductive foil 1.
[0034] Specifically, the rubber strip 601 is embedded inside the braided fiber sleeve 6, and the rubber strip 601 is distributed in an array about the inner wall of the braided fiber sleeve 6. The vertical cross-section of the rubber strip 601 is circular. The braided fiber sleeve 6 is made of aramid fiber and carbon fiber mixed and woven with a weaving density of 80–120 mesh.
[0035] In this implementation plan, such as Figure 4 As shown, the rubber strip 601 is mainly used to support the interior of the braided fiber sheath 6, thereby improving the bending strength of the braided fiber sheath 6 and meeting the bending protection requirements of the cable.
[0036] In this embodiment, please refer to Figure 1 , Figure 2 and Figure 3 The heat-conducting layer 5 includes a heat-dissipating sleeve 501 and a heat-conducting grease layer 502. The heat-dissipating sleeve 501 is fixedly attached to the inner surface of the braided fiber sleeve 6, and the heat-conducting grease layer 502 is fixedly covered on the outer surface of the insulating sleeve 3.
[0037] Specifically, the interior of the heat dissipation sleeve 501 is filled with ceramic thermally conductive particles, and the outer surface of the thermal grease layer 502 is integrally formed with the inner wall of the heat dissipation sleeve 501.
[0038] In this embodiment, the thermal grease layer 502 ensures uniform absorption of the heat released by the conductive foil 1, while the ceramic thermally conductive particles inside the heat dissipation sheath 501 can quickly conduct the heat to the external environment. This helps to prevent the cable from being damaged by overheating when high current passes through, thereby extending the service life of the cable.
[0039] The working process of this utility model is as follows: When using a high-current flexible busbar cable, the combination of rubber strip 601 and braided fiber sleeve 6 can effectively improve the bending resistance of the busbar cable, thereby effectively preventing the insulation layer from cracking due to stress concentration when the cable is bent, thus meeting the cable's usage requirements. When the current generates heat through the conductive foil 1, the heat is transferred to the thermal grease layer 502 through the buffer layer 4 and the insulating sleeve 3. The thermal grease layer 502 can absorb the heat and conduct it to the ceramic particles inside the heat dissipation sheath 501, and then dissipate it to the external environment through the sheath layer 2, ensuring the working environment of the cable.
[0040] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A high-current flexible busbar cable, comprising conductive foil (1) and a sheath layer (2), characterized in that: The conductive foil (1) is covered with an insulating sleeve (3) on the outside. A buffer layer (4) is provided between the insulating sleeve (3) and the conductive foil (1). A heat-conducting layer (5) is provided on the outside of the insulating sleeve (3). A braided fiber sleeve (6) is provided on the inside of the sheath layer (2). A rubber strip (601) is provided inside the braided fiber sleeve (6).
2. A high current flexible busbar cable according to claim 1, characterized in that: The heat-conducting layer (5) includes a heat-dissipating sleeve (501) and a heat-conducting grease layer (502). The heat-dissipating sleeve (501) is fixedly attached to the inner surface of the braided fiber sleeve (6), and the heat-conducting grease layer (502) is fixedly covered on the outer surface of the insulating sleeve (3).
3. A high current flexible busbar cable according to claim 2, characterized in that: The interior of the heat dissipation sleeve (501) is filled with ceramic thermally conductive particles, and the outer surface of the thermally conductive grease layer (502) is integrally formed with the inner wall of the heat dissipation sleeve (501).
4. A high current flexible busbar cable according to claim 1, characterized in that: The insulating sleeve (3) is made of a flexible polymer film.
5. A high current flexible busbar cable according to claim 1, characterized in that: The rubber strip (601) is embedded inside the woven fiber sleeve (6), and the rubber strip (601) is arranged in an array about the inner wall of the woven fiber sleeve (6).
6. A high current flexible busbar cable according to claim 1, characterized in that: The vertical cross-section of the rubber strip (601) is circular.
7. A high current flexible busbar cable according to claim 1, characterized in that: The buffer layer (4) is a porous fluoropolymer film, and the thickness of the buffer layer (4) is 0.05–0.2 mm.
8. A high current flexible busbar cable according to claim 1, characterized in that: The woven fiber sleeve (6) is made of aramid fiber and carbon fiber mixed together, with a weaving density of 80–120 mesh.