Temperature adjustable photovoltaic cable

Abstract

This utility model belongs to the field of cable technology, specifically relating to a temperature-adjustable photovoltaic cable, including a cable core, which is formed by stranding multiple wire cores and multiple fillers together. The number of wire cores and fillers are equal and they are evenly and alternately arranged in the circumferential direction of the cable core. An isolation sleeve covers the cable core; an armor layer covers the isolation sleeve; and an outer sheath covers the armor layer. The fillers include a metal tubing and a phase-change heat storage material filled within the metal tubing. This utility model enables the cable to have an adaptive temperature regulation function, effectively maintaining the temperature range of the cable core, suppressing operating temperature fluctuations, improving the safety and stability of the cable in harsh environments, reducing the impact of high-temperature aging and low-temperature embrittlement on electrical and physical properties, ensuring the cable better adapts to outdoor environments with large temperature differences, while maintaining a compact structural design without requiring additional space.

Description

Technical Field

[0001] This utility model belongs to the field of cable technology, specifically relating to an adjustable temperature photovoltaic cable. Background Technology

[0002] In photovoltaic power generation systems, photovoltaic cables, as the core carriers of energy transmission, are exposed to extreme climates with drastic day-night temperature differences (daily temperature differences often exceed 40°C) for extended periods. In high-temperature environments, the cable insulation layer ages faster due to the high temperature, leading to a decrease in volume resistivity and an increase in dielectric loss. In frigid environments, the polymer sheath is prone to low-temperature embrittlement and cracking, causing moisture penetration and insulation failure.

[0003] However, the filling materials of current photovoltaic cables are mainly passive insulation types, including fiberglass rope and polypropylene. They only achieve static physical support and lack dynamic temperature regulation capabilities. Therefore, they are unable to smooth out temperature peaks and troughs and cannot simultaneously suppress high-temperature aging and low-temperature embrittlement, resulting in poor operational stability and service life of photovoltaic cables. Utility Model Content

[0004] The purpose of this invention is to provide a temperature-adjustable photovoltaic cable, which solves the technical problem that existing photovoltaic cables lack dynamic temperature adjustment capabilities.

[0005] This utility model discloses a temperature-adjustable photovoltaic cable, comprising:

[0006] The cable core is formed by twisting together multiple wire cores and multiple filler elements. The number of wire cores and filler elements is the same, and they are arranged alternately and evenly in the circumferential direction of the cable core.

[0007] An isolation sleeve covers the outside of the cable core;

[0008] An armor layer covers the outside of the isolation sleeve;

[0009] An outer sheath covers the armor layer.

[0010] The filling component includes a metal sleeve and a phase change heat storage material filled inside the metal sleeve. The phase change heat storage material is used to regulate the temperature of the cable core by absorbing or releasing heat.

[0011] This application uses a metal sleeve containing phase change heat storage material as a filler, which is alternately and evenly twisted with the wire core. This enables the cable to have an adaptive temperature regulation function, effectively maintaining the temperature range of the cable core, suppressing operating temperature fluctuations, improving the safety and stability of the cable in harsh environments, reducing the impact of high-temperature aging and low-temperature embrittlement on electrical and physical properties, ensuring that the cable can better adapt to outdoor environments with large temperature differences, while maintaining a compact structural design without taking up additional space.

[0012] Based on the above technical solution, the solution of this application can be further improved as follows:

[0013] Preferably, the filler has a fan-shaped structure in radial cross-section, with an outer convex arc surface on its outer side for fitting against the inner wall of the isolation sleeve, and an inner concave arc surface on its inner side for fitting against the outer peripheral surface of the adjacent wire core. This design utilizes the interlocking structure formed by the concave and convex arc surfaces to evenly distribute mechanical stress, resist extrusion deformation, improve torsional resistance and structural stability, enhance heat conduction efficiency, ensure uniform cable core temperature, eliminate redundant gaps, and optimize the roundness and space utilization of the cable core.

[0014] Preferably, the phase change heat storage material is a copper foam-paraffin composite phase change heat storage material; by adopting this solution, a balance is achieved between the contradictory balance of heat storage capacity, thermal conductivity and mechanical reliability, making it suitable for long-term temperature control in harsh outdoor environments.

[0015] Preferably, the filler includes:

[0016] A waterproof coating is applied to the inner wall of the metal sleeve. This solution forms an anti-permeability barrier, preventing moisture from eroding the phase change heat storage material, solving the hidden dangers of hydrolysis, deterioration, and electrochemical corrosion, and ensuring long-term stability under harsh conditions.

[0017] Preferably, the wire core comprises:

[0018] conductor;

[0019] An insulation layer is wrapped around the conductor; this solution improves the mechanical and physical properties, electrical properties, and flame retardant properties of the cable, ensuring long-term operational stability.

[0020] Preferably, it further includes:

[0021] The first wrapping tape covers the outside of the cable core and is located inside the isolation sleeve;

[0022] The second wrapping tape covers the outside of the armor layer and is located inside the outer sheath. This solution locks and solidifies the cable core structure, reduces the risk of wear, blocks the longitudinal penetration path of water vapor, improves waterproofing, and can also elastically buffer and absorb the stress deformation of the armor layer, prevent sharp edges from piercing the outer sheath, and significantly improve tensile strength.

[0023] Preferably, it further includes:

[0024] A light-shielding self-healing coating is applied to the outer periphery of the outer sheath. This solution utilizes its excellent hydrophobic properties, ultraviolet light shielding properties, and repeated self-healing properties to effectively protect the cable from moisture, ultraviolet rays, and external force damage, thereby improving the cable's service life in harsh outdoor environments such as those with large humidity variations and abundant sunlight.

[0025] Through the above technical solution, this utility model achieves the following beneficial effects:

[0026] 1. This application uses a metal sleeve containing phase change heat storage material as a filler, which is alternately and evenly twisted with the wire core. This enables the cable to have an adaptive temperature regulation function, effectively maintaining the temperature range of the cable core, suppressing operating temperature fluctuations, improving the safety and stability of the cable in harsh environments, reducing the impact of high-temperature aging and low-temperature embrittlement on electrical and physical properties, ensuring that the cable can better adapt to outdoor environments with large temperature differences, while maintaining a compact structural design without taking up additional space.

[0027] 2. This application utilizes concave and convex arc surfaces to form an interlocking structure, which uniformly disperses mechanical stress, resists extrusion deformation, and improves torsional resistance and structural stability. Furthermore, the concave arc surface maximizes the contact area with the wire core, thereby improving heat conduction efficiency. The convex arc surface promotes heat diffusion to the isolation sleeve, ensuring a uniform temperature of the cable core. Moreover, the fan-shaped cross-section fully fills the gaps between the wire cores, eliminating redundant gaps and optimizing the roundness and space utilization of the cable core. Attached Figure Description

[0028] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0029] Figure 1 This is a schematic diagram of the structure of the adjustable temperature photovoltaic cable according to a specific embodiment of the present invention;

[0030] Figure 2 for Figure 1 The diagram shows the structure of the filler in the adjustable temperature photovoltaic cable.

[0031] Explanation of reference numerals in the attached figures:

[0032] 1. Cable core; 11. Wire core; 111. Conductor; 112. Insulation layer; 12. Filler; 1201. Outer convex arc surface; 1202. Inner concave arc surface; 121. Metal sleeve; 122. Phase change heat storage material; 123. Waterproof coating; 2. Isolation sleeve; 3. Armor layer; 4. Outer sheath; 5. First wrapping tape; 6. Second wrapping tape; 7. Light-proof self-healing coating. Detailed Implementation

[0033] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings. These embodiments are merely illustrative of the present invention and should not be construed as limiting the scope of protection of the present invention.

[0034] The terms “first” and “second” are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as “first” or “second” may explicitly or implicitly include one or more of the stated features.

[0035] In this application, unless otherwise expressly specified and limited, the terms "installation" and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0036] To better understand the above technical solutions, the following will provide a detailed description of the technical solutions in conjunction with the accompanying drawings and specific embodiments.

[0037] Example:

[0038] like Figure 1 and Figure 2 As shown in the figure, this application discloses a temperature-adjustable photovoltaic cable, which can realize automatic temperature adjustment function, improve the safety, stability and service life of the cable. The specific structure includes: cable core 1, isolation sleeve 2, armor layer 3 and outer sheath 4.

[0039] The cable core 1 is formed by twisting together multiple wire cores 11 and multiple filler elements 12. The number of wire cores 11 and filler elements 12 is the same, and they are evenly and alternately arranged in the circumferential direction of the cable core 1. This makes the cross-sectional structure of the cable stable and round, and allows heat to be conducted and dissipated more evenly inside the cable core 1, thereby achieving a more balanced temperature regulation effect.

[0040] The filler 12 includes a metal sleeve 121 and a phase change heat storage material 122 filled in the metal sleeve 121. The phase change heat storage material 122 is used to regulate the temperature of the cable core 1 by absorbing or releasing heat.

[0041] Specifically, the metal sleeve 121 can be made of materials such as copper, aluminum or silver with a certain thickness, and is used to tightly seal the phase change heat storage material 122 to prevent it from leaking and contaminating the core 11 or other structures; it has good thermal conductivity, which can quickly transfer the heat generated by the core 11 to the internal phase change heat storage material 122, and can also quickly transfer the heat released by the phase change heat storage material 122 back to the core 11 or dissipate it, ensuring the efficiency of heat exchange; it also serves as the main body of the filler 12, providing structural strength and enabling it to be twisted into a stable cable core 1 structure.

[0042] Understandably, when the temperature of the core 11 rises, the phase change heat storage material 122 absorbs a large amount of heat and changes from solid to liquid, thereby preventing the temperature of the core 1 from rising too quickly and too high, and avoiding high-temperature aging; when the cable temperature drops, the phase change heat storage material 122 releases the stored heat and solidifies from liquid to solid, thereby slowing down the rate of temperature drop of the core 1 and avoiding low-temperature embrittlement.

[0043] The isolation sleeve 2 covers the outside of the cable core 1 and is used to isolate the cable core 1 from the armor layer 3, so as to prevent the cable core 1 from being crushed or damaged by the armor layer 3. It can be made by extrusion of irradiated cross-linked halogen-free low-smoke flame-retardant polyolefin sheath material, which has flame-retardant and environmentally friendly effects.

[0044] The armor layer 3 covers the outer side of the isolation sleeve 2. It preferably adopts a single-layer circular or tile-shaped metal wire tightly wrapped structure, which provides strong resistance to pressure, impact, tension and torsion. While preventing mechanical damage, it ensures that the cable structure is compact and complete and the electrical performance is stable.

[0045] The outer sheath 4 covers the armor layer 3 and can be made by extrusion of irradiated cross-linked halogen-free low-smoke flame-retardant polyolefin sheath material with salt spray, damp heat and acid and alkali resistance properties, so that the cable can be environmentally friendly and flame-retardant while being resistant to certain salt spray, damp heat and acid and alkali environments.

[0046] This invention uses a metal sleeve 121 encapsulated with phase change heat storage material 122 as a filler 12, which is alternately and uniformly twisted with the wire core 11. This enables the cable to have an adaptive temperature regulation function, effectively maintaining the temperature range of the cable core 1, suppressing operating temperature fluctuations, improving the safety and stability of the cable in harsh environments, reducing the impact of high-temperature aging and low-temperature embrittlement on electrical and physical properties, ensuring that the cable can better adapt to outdoor environments with large temperature differences, while maintaining a compact structural design without occupying additional space.

[0047] In some embodiments, such as Figure 2 As shown, the filler 12 has a fan-shaped structure in the radial section to fit the circumferential spatial distribution during twisting. Its outer side has an outwardly convex arc surface 1201 for fitting against the inner wall of the isolation sleeve 2, and its inner side has an inwardly concave arc surface 1202 for fitting against the outer circumferential surface of the adjacent wire core 11.

[0048] Understandably, the fit between the convex arc surface 1201 and the isolation sleeve 2 can evenly distribute the radial pressure applied by the armor layer 3 to each filler 12, avoiding the occurrence of local stress concentration that could lead to deformation of the wire core 11; the concave arc surface 1202 can limit and fix the wire core 11, restricting the displacement of the wire core 11 when it is bent or compressed, thus reducing the risk of mechanical damage.

[0049] Understandably, the fan-shaped structure allows the wire core 11 and the filler 12 to be arranged alternately at equal intervals in the circumferential direction, thereby promoting the overall temperature balance of the cable core 1 and avoiding local overheating; the concave arc surface 1202 maximizes the contact area between the filler 12 and the wire core 11, enabling the phase change heat storage material 122 to quickly absorb the heat generated by the wire core 11 through the metal sleeve 121, thereby improving the heat conduction efficiency.

[0050] Understandably, the fan-shaped cross section fully fills the gaps after the core 11 is twisted, eliminating redundant space, improving the roundness of the cable core 1, and the interlocking design of the concave and convex arc surfaces improves the structural rigidity of the cable core 1, reduces relative slippage, alleviates vibration and pressure, and extends service life.

[0051] Through the above configuration, the interlocking structure formed by the concave and convex arc surfaces evenly disperses mechanical stress, resists extrusion deformation, and improves torsional resistance and structural stability. The concave arc surface 1202 maximizes the contact area with the wire core 11, improving heat conduction efficiency. The convex arc surface 1201 promotes heat diffusion to the isolation sleeve 2, ensuring a uniform temperature of the cable core 1. Furthermore, the fan-shaped cross-section fully fills the gaps between the wire cores 11, eliminating redundant gaps and optimizing the roundness and space utilization of the cable core 1.

[0052] In some embodiments, the phase change heat storage material 122 is a copper foam-paraffin composite phase change heat storage material, that is, a composite phase change heat storage material is made by filling copper foam with liquid paraffin.

[0053] It should be noted that foamed copper-paraffin composite phase change thermal storage materials are existing technologies and are mainly used in scenarios such as energy storage radiators, spacecraft electronic equipment, or cabin temperature regulation.

[0054] Understandably, the three-dimensional mesh skeleton of copper foam forms an ultra-high thermal conductivity pathway, completely solving the core bottleneck of poor thermal conductivity of paraffin and realizing rapid heat transfer; moreover, the skeleton of copper foam can bind the flow of liquid paraffin, inhibit phase separation, and ensure that the performance does not degrade after multiple phase change cycles, making it particularly suitable for the day and night temperature difference cycle conditions of photovoltaic cables.

[0055] Preferably, the paraffin filling rate can be 20%±5%, which balances the heat storage capacity and structural strength, ensures the mechanical support of the foamed copper skeleton, and reserves space for the expansion of paraffin phase change to avoid the sleeve from cracking.

[0056] When the cable temperature is too high, the foamed copper, which has excellent thermal conductivity, will absorb heat and transfer it to the paraffin. When the temperature reaches the melting point of the paraffin, the paraffin absorbs heat and melts, further helping the cable dissipate heat. When the ambient temperature is too low, the cable temperature is also low. At this time, the paraffin will solidify and release heat. The heat is dissipated to other structures of the cable through the foamed copper, thus protecting the cable.

[0057] The above settings achieve a balance between heat storage, thermal conductivity, and mechanical reliability, making it suitable for long-term temperature control in harsh outdoor environments.

[0058] In some embodiments, such as Figure 2 As shown, the filler 12 also includes a waterproof coating 123, which is applied to the inner wall of the metal sleeve 121.

[0059] Through the above settings, an anti-permeability barrier is formed, which blocks the moisture from eroding the phase change heat storage material 122, solves the hidden dangers of hydrolysis deterioration and electrochemical corrosion, and ensures long-term stability under harsh conditions.

[0060] In some embodiments, such as Figure 2 As shown, the wire core 11 includes:

[0061] Conductor 111 is made of tin-plated Class 5 copper conductor or aluminum alloy conductor to ensure that the cable conductor has good oxidation resistance and that the cable can operate stably in humid environments.

[0062] The insulation layer 112, which covers the conductor 111, can be extruded using irradiated cross-linked halogen-free low-smoke flame-retardant polyolefin insulation material to ensure that the cable has excellent mechanical and physical properties, electrical properties and flame-retardant properties.

[0063] The above design of core 11 improves the mechanical and physical properties, electrical properties, and flame retardant properties of the cable, ensuring long-term operational stability.

[0064] In some embodiments, such as Figure 1 As shown, it also includes:

[0065] The first wrapping tape 5 covers the outside of the cable core 1 and is located inside the isolation sleeve 2. It is used to lock and solidify the structure of the cable core 1, suppress the micro-friction of the wire core 11, thereby reducing the risk of wear and blocking the longitudinal penetration path of water vapor, and improving the waterproof capability.

[0066] The second strap 6 covers the armor layer 3 and is located inside the outer sheath 4. It can elastically buffer and absorb the stress deformation of the armor layer 3, prevent sharp edges from piercing the outer sheath 4, and greatly improve the tensile strength.

[0067] In some embodiments, such as Figure 1 As shown, it also includes: a light-shielding self-healing coating 7, which is applied to the outer periphery of the outer sheath 4.

[0068] Specifically, the light-shielding self-healing coating 7 is mainly composed of cyclodextrin-modified titanium dioxide, adamantine, esterification products of 2-hydroxyethyl-methacrylate (HEMA), and butyl acrylate. It exhibits good hydrophobicity, low moisture absorption, excellent UV shielding performance, and good repeated self-healing ability. It helps cable insulation materials avoid insulation performance degradation caused by humidity, effectively prevents photodegradation of the cable outer sheath under UV irradiation, and spontaneously repairs scratches and severe friction damage. In particular, it can achieve repeated self-healing at the same location (at least 3 times), and the tensile properties after self-healing can recover more than 80%.

[0069] It should be noted that this light-shielding self-healing material is a known material, and there is a relevant record in the "Journal of Chemical Research in Chinese Universities", with the title of the paper "Preparation and Performance of Light-Shielding Self-Healing Coating for Cable Sheaths".

[0070] By setting a light-shielding self-healing coating 7, the cable can be effectively protected from moisture, ultraviolet light and external force damage by utilizing its excellent hydrophobic properties, ultraviolet light shielding properties and repeated self-healing properties, thereby improving the service life of the cable in harsh outdoor environments such as large humidity changes and strong sunlight.

[0071] Further explanation regarding this application:

[0072] When the temperature of the photovoltaic cable core 1 rises, the heat is first conducted to the filler 12 around the core 11. Due to its excellent thermal conductivity, the metal sleeve 121 outside the filler 12 quickly transfers the heat from the core 11 and the surrounding environment to the internal phase change heat storage material 122. When the temperature of the phase change heat storage material 122 reaches its preset phase change temperature, it begins to melt from a solid to a liquid state. This melting process absorbs a large amount of latent heat. Since the temperature of the phase change heat storage material 122 remains basically unchanged during the phase change process (maintained near the phase change temperature), it effectively prevents the rapid rise of the core 1 temperature, avoids the core 1 temperature from becoming too high, thereby reducing the rate of aging of the insulation material due to high temperature, improving the safety margin of the cable, and reducing the risk of overheating.

[0073] When the temperature of the photovoltaic cable core 1 decreases: the core 1 begins to dissipate heat to the surrounding environment, and the temperature tends to decrease. The metal sheath 121 efficiently transfers heat from the internal phase change heat storage material 122. When the temperature of the phase change heat storage material 122 drops below its phase change temperature, it begins to solidify from a liquid state to a solid state. This solidification process releases an equal amount of latent heat that was previously absorbed. Part of the released latent heat is dissipated into the environment, but the other part is transferred back to the nearby core 11. Since the temperature of the phase change heat storage material 122 remains basically unchanged during the solidification process (maintained near the phase change temperature), the rate of temperature decrease of the core 1 is slowed down, avoiding the core 1 temperature from becoming too low. This prevents the insulation sheath material from becoming brittle at low temperatures and maintains good flexibility and mechanical properties.

[0074] Numerous specific details are set forth in this specification. However, it will be understood that embodiments of this invention may be practiced without these specific details. In some instances, well-known methods, structures, and techniques have not been shown in detail so as not to obscure the understanding of this specification.

[0075] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0076] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model, and they should all be covered within the scope of the claims and specification of this utility model.

Claims

1. A temperature-regulated photovoltaic cable, characterized by The application relates to a cable, which comprises: a cable core formed by twisting a plurality of wire cores and a plurality of fillers together, the wire cores and the fillers being arranged alternately and uniformly in the circumferential direction of the cable core; an isolation sleeve covering the cable core; an armor layer covering the isolation sleeve; an outer sheath covering the armor layer; wherein the fillers comprise metal sleeves and phase change heat storage materials filled in the metal sleeves, and the phase change heat storage materials are used for adjusting the temperature of the cable core by absorbing or releasing heat.

2. The temperature-regulated photovoltaic cable according to claim 1, characterized in that, The fillers have a fan-shaped structure in a radial cross section, and the outer side of the fillers has an outer convex arc surface used for abutting against the inner wall of the isolation sleeve, and the inner side of the fillers has an inner concave arc surface used for abutting against the outer circumferential surface of the adjacent wire cores.

3. The temperature-regulated photovoltaic cable according to claim 1, characterized in that, The phase change heat storage materials are foam copper-paraffin composite phase change heat storage materials.

4. The temperature-regulated photovoltaic cable of claim 1, wherein, The fillers comprise: a waterproof coating coated on the inner wall of the metal sleeve.

5. The temperature-regulated photovoltaic cable of claim 1, wherein, The wire cores comprise: a conductor; an insulation layer covering the conductor.

6. The temperature-regulated photovoltaic cable of claim 1, wherein, The application further comprises: a first wrapping tape covering the cable core and located on the inner side of the isolation sleeve; a second wrapping tape covering the armor layer and located on the inner side of the outer sheath.

7. The temperature-regulated photovoltaic cable of claim 1, wherein, The application further comprises: a light-proof self-healing coating coated on the outer circumferential surface of the outer sheath.

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