High-voltage wire for subway train with high conductivity

Abstract

The utility model provides a kind of high pressure conductor for subway train with high conductivity, it is related to high pressure conductor technical field, the utility model includes conductor core and insulating layer, the conductor core is made of copper or aluminium with purity ≥99.99%, surface is covered with the graphene coating with thickness 0.1-1 microns, conductor core adopts multiple strand structure, each strand conductor is composed of 19 soft round filaments with diameter 0.1-0.3 millimeter, the insulating layer is high-temperature-resistant silicone rubber material, the outside of the insulating layer is provided with moisture-proof layer and protective layer, the utility model is by adopting conductor core as copper or aluminium conductor with purity ≥99.99%, and is combined 0.1-1 microns graphene coating, improves the conductivity of conductor core, and significantly prolongs the life of conductor by the antioxidant property of graphene, and the combination of insulating layer, moisture-proof layer and protective layer made of high-temperature-resistant silicone rubber can meet the high temperature, humidity and mechanical wear requirements of subway environment simultaneously, further improve the service life of high pressure conductor.

Description

Technical Field

[0001] This utility model relates to the field of high-voltage conductor technology, and in particular to a high-voltage conductor for subway trains with high conductivity. Background Technology

[0002] The high-voltage conductors of subway trains are key electrical components in the subway power supply system used to transmit high voltage and high current. They are mainly responsible for transmitting electrical energy from the traction substation or the third rail / overhead contact network to the train traction system.

[0003] Currently, the high-voltage conductors used in subway trains use copper conductors, which have high conductivity (100% IACS), but are heavy (8.96g / cm³) and prone to oxidation. Aluminum conductors are lightweight (2.7g / cm³), but their conductivity is only 61% IACS, requiring an increased cross-sectional area to meet current carrying capacity. However, this increases the conductor volume. In addition, existing insulation materials (such as ethylene propylene rubber) typically have a long-term operating temperature of ≤90℃, which can easily lead to insulation aging due to heat generation during high-load train operation, resulting in a reduced conductor lifespan. Utility Model Content

[0004] To address the shortcomings of existing technologies, this invention provides a high-voltage conductor for subway trains with high conductivity. Through multiple innovations in materials, structure, and processes, the overall performance of the high-voltage conductor for subway trains can be significantly improved.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a high-voltage conductor for subway trains with high conductivity, comprising a conductor core and an insulation layer. The conductor core is made of copper or aluminum with a purity of ≥99.99%, and its surface is covered with a graphene coating with a thickness of 0.1-1 micrometer. The conductor core adopts a multi-strand stranded structure, and each conductor consists of 19 soft round monofilaments with a diameter of 0.1-0.3 mm. The insulation layer is made of high-temperature resistant silicone rubber, and a moisture-proof layer and a protective layer are provided on the outside of the insulation layer.

[0006] The effects achieved by the above components are as follows: by using copper or aluminum conductor cores with a purity of ≥99.99%, the conductivity breaks through the 100% IACS limit of traditional copper wires, reaching more than 102% IACS. The graphene coating forms a conductive network through atomic-level bonding, which not only improves the current carrying capacity, but also inhibits conductor oxidation through physical barrier effect, thus extending the service life of the wire.

[0007] Preferably, the graphene coating is formed in situ on the surface of the conductor core by chemical vapor deposition, the number of graphene layers is 1-3, and the bonding strength between the graphene layer and the conductor core is ≥5N / mm.

[0008] The effects achieved by the above components are as follows: by forming 1-3 layers of graphene on the conductor surface through methane decomposition, the coating peeling problem of traditional spraying process can be avoided. The graphene prepared by this method has a bonding strength with the conductor core of ≥5N / mm, and the carrier mobility of single-layer graphene reaches 200,000 cm² / (V・s), which can form an electronic highway on the conductor core surface, reducing high-frequency current transmission loss by more than 15%.

[0009] Preferably, the stranding pitch of the multi-strand stranded structure is 8-12 times the conductor core diameter, and nano-ceramic particles are filled between each conductor, with a filling density ≥85%.

[0010] The effects achieved by the above components are as follows: by optimizing the stranding pitch of 19 monofilaments per strand, the skin depth is reduced from 6.6 mm (50 Hz) of the solid conductor to 2.1 mm, and the high-frequency transmission efficiency is increased by more than 30%. Filling the gaps between the strands with aluminum nitride nanoparticles can enhance the structural stability of the conductor core and reduce the overall temperature of the conductor core by 8-12°C through the phonon heat conduction mechanism.

[0011] Preferably, the conductor core has a cross-sectional area of ​​50-240 square millimeters, a DC resistance of ≤0.0718Ω / km (20℃), and a conductivity of ≥102% IACS.

[0012] The effect achieved by the above components is that when using aluminum alloy conductors, the weight is reduced by 60% compared to copper conductors under the same current carrying capacity, while the conductivity is still maintained at 98% IACS, meeting the lightweight requirements of subways.

[0013] Preferably, the thickness of the insulating layer is 0.5-1.5 mm, and the long-term temperature resistance is ≥150℃; the thickness of the moisture-proof layer is 0.3-0.8 mm, and the water absorption rate is ≤0.1%; the thickness of the protective layer is 0.2-0.5 mm, and the surface hardness is ≥Shore A85.

[0014] The effects achieved by the above components are as follows: by using a protective layer made of methyl vinyl silicone rubber, the tensile strength retention rate of the high-voltage conductor is ≥85% during long-term operation at 150°C, which is more durable than the 60% of traditional ethylene propylene rubber. Furthermore, due to the tight arrangement of high-density polyethylene molecular chains, the water absorption rate is ≤0.1%, and the insulation resistance retention rate is ≥98% in an environment with 95% RH humidity. The polyurethane layer with Shore A85 hardness can resist a frictional torque of 0.5 N·m.

[0015] Preferably, the insulating layer is further provided with a metal shielding layer and an interlocking armor layer, wherein the metal shielding layer is a tin-plated copper wire braided layer with a shielding efficiency ≥90dB.

[0016] The effect achieved by the above components is that by setting up a braided structure with 85% coverage, electromagnetic interference in the 30-1000MHz frequency band can be effectively suppressed, ensuring the stability of signal transmission in the train control system.

[0017] Preferably, the interlocking armor layer is an aluminum alloy strip wrapping structure with a thickness ≥1.1 mm, using 3003 aluminum alloy strip wrapping.

[0018] The above-mentioned components achieve the following effects: tensile strength ≥120MPa, weight reduced by 50% compared to traditional steel belt armor, and provide equivalent radial compressive strength of 10kN through interlocking structure.

[0019] Compared with the prior art, the advantages and positive effects of this utility model are as follows: (1) In this utility model, by using a copper or aluminum conductor with a purity of ≥99.99% as the conductor core and combining it with a 0.1-1 micrometer graphene coating, the conductivity of the conductor core is improved, and the life of the wire is significantly extended by the antioxidant properties of graphene.

[0020] (2) By using a conductor core with a stranded structure of 19 soft round monofilaments and filled with nano-ceramic particles, the skin effect can be reduced by more than 30%, thereby improving the efficiency of high-frequency power transmission.

[0021] (3) By using a combination of insulation, moisture-proof and protective layers made of high-temperature resistant silicone rubber, the high temperature, humidity and mechanical wear requirements of the subway environment can be met at the same time, further improving the service life of high-voltage conductors. Attached Figure Description

[0022] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This is a partial cross-sectional three-dimensional structural diagram of the protective layer of this utility model; Figure 3 This utility model Figure 2 A magnified three-dimensional structural diagram of point A.

[0023] Legend: 1. Insulation layer; 2. Conductor core; 3. Graphene coating; 4. Moisture-proof layer; 5. Protective layer; 6. Metal shielding layer; 7. Interlocking armor layer. Detailed Implementation

[0024] Example 1, as Figure 1-3As shown, a high-voltage conductor for subway trains with high conductivity includes a conductor core 2 and an insulation layer 1. The conductor core 2 is made of copper or aluminum with a purity ≥99.99%, and its surface is covered with a graphene coating 3 with a thickness of 0.1-1 micrometer. The conductor core 2 adopts a multi-strand stranded structure, and each conductor consists of 19 soft round monofilaments with a diameter of 0.1-0.3 mm. The insulation layer 1 is made of high-temperature resistant silicone rubber. A moisture-proof layer 4 and a protective layer 5 are provided on the outside of the insulation layer 1. By using a copper or aluminum conductor core 2 with a purity ≥99.99%, the conductivity breaks through the 100% IACS limit of traditional copper conductors, reaching more than 102% IACS. The graphene coating 3 forms a conductive network through atomic-level bonding, which not only improves the current carrying capacity, but also inhibits conductor oxidation through physical barrier effect, extending the service life of the conductor.

[0025] Reference Figure 2-3 As shown in this embodiment: the graphene coating 3 is formed in situ on the surface of the conductor core 2 by chemical vapor deposition, with 1-3 graphene layers. The bonding strength between the graphene layers and the conductor core 2 is ≥5N / mm. Forming 1-3 layers of graphene on the conductor surface through methane decomposition avoids the coating peeling problem of traditional spraying processes. The graphene prepared by this method has a bonding strength ≥5N / mm with the conductor core 2, and the carrier mobility of a single-layer graphene reaches 200,000 cm² / (V・s), forming an electronic highway on the surface of the conductor core 2, reducing high-frequency current transmission loss by more than 15%. The stranding pitch of the multi-strand stranded structure is 8-12 times the diameter of the conductor core 2, and nano-ceramic particles are filled between each conductor strand with a filling density ≥85%. By optimizing the stranding pitch of the 19 monofilaments per strand, the skin depth is reduced from 6.6mm at 50Hz for solid conductors to 2.1mm, improving high-frequency transmission efficiency by 30%. In summary, filling the gaps between the strands with aluminum nitride nanoparticles can enhance the structural stability of conductor core 2 and reduce the overall temperature of conductor core 2 by 8-12℃ through phonon thermal conduction mechanism. The cross-sectional area of ​​conductor core 2 is 50-240 square millimeters, the DC resistance is ≤0.0718Ω / km20℃, and the conductivity is ≥102% IACS. When using aluminum alloy conductors, the weight is reduced by 60% compared with copper conductors under the same current carrying capacity, while the conductivity is still maintained at 98% IACS, meeting the lightweight requirements of subways.

[0026] Reference Figure 2-3As shown in this embodiment: the thickness of insulation layer 1 is 0.5-1.5 mm, with a long-term temperature resistance ≥150℃; the thickness of moisture-proof layer 4 is 0.3-0.8 mm, with a water absorption rate ≤0.1%; the thickness of protective layer 5 is 0.2-0.5 mm, with a surface hardness ≥Shore A85. Using methyl vinyl silicone rubber, protective layer 5 maintains a tensile strength retention rate of ≥85% for high-voltage conductors during long-term operation at 150℃, which is more durable than the 60% retention rate of traditional ethylene propylene rubber. Through the tight arrangement of high-density polyethylene molecular chains, the water absorption rate is ≤0.1%, and the insulation resistance retention rate is ≥98% in a 95% RH environment. The polyurethane layer with a Shore A85 hardness can resist a frictional torque of 0.5 N·m. Outside insulation layer 1, there is also a metal shielding layer 6 and an interlocking armor layer 7. The metal shielding layer 6 is a tin-plated copper wire braided layer with a shielding efficiency ≥90dB. By setting an 85% coverage braided structure, it can effectively suppress 30-1000MHz... To mitigate electromagnetic interference in the frequency band and ensure the stability of signal transmission in the train control system, the interlocking armor layer 7 is an aluminum alloy strip wrapping structure with a thickness of ≥1.1 mm. By using 3003 aluminum alloy strip wrapping, the tensile strength is ≥120MPa, and the weight is reduced by 50% compared to traditional steel strip armor. At the same time, the interlocking structure provides an equivalent radial compressive strength of 10kN.

[0027] Working principle: When in use, this high-voltage conductor uses a copper or aluminum conductor with a purity of ≥99.99% for the conductor core 2, combined with a 0.1-1 micrometer graphene coating 3 to improve the conductivity of the conductor core 2. The oxidation resistance of graphene significantly extends the life of the conductor. By using a 19-strand soft round monofilament structure for the conductor core 2, combined with nano-ceramic particle filling, the skin effect can be reduced by more than 30%, improving the high-frequency power transmission efficiency. The combination of an insulation layer 1, a moisture-proof layer 4, and a protective layer 5 made of high-temperature resistant silicone rubber can simultaneously meet the requirements of high temperature, humidity, and mechanical wear in the subway environment, further extending the service life of the high-voltage conductor.

[0028] The above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model in any other way. Any person skilled in the art may use the disclosed technical content to make changes or modifications to create equivalent embodiments for application in other fields. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of this utility model, without departing from the scope of the utility model's technical solution, still fall within the protection scope of this utility model's technical solution. In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" 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 mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood through specific circumstances.

Claims

1. A high-voltage conductor for subway trains with high conductivity, comprising a conductor core (2) and an insulation layer (1), characterized in that: The conductor core (2) is made of copper or aluminum with a purity of ≥99.99%, and the surface is covered with a graphene coating (3) with a thickness of 0.1-1 micrometer. The conductor core (2) adopts a multi-strand stranded structure, and each conductor consists of 19 soft round monofilaments with a diameter of 0.1-0.3 mm. The insulation layer (1) is made of high temperature resistant silicone rubber. A moisture-proof layer (4) and a protective layer (5) are provided on the outside of the insulation layer (1).

2. The high-voltage conductor for subway trains with high conductivity according to claim 1, characterized in that: The graphene coating (3) is formed in situ on the surface of the conductor core (2) by chemical vapor deposition. The number of graphene layers is 1-3, and the bonding strength between the graphene layer and the conductor core (2) is ≥5N / mm. 1-3 layers of graphene are formed on the conductor surface by the decomposition of methane.

3. The high-voltage conductor for subway trains with high conductivity according to claim 2, characterized in that: The stranding pitch of the multi-strand stranded structure is 8-12 times the diameter of the conductor core (2), and nano-ceramic particles are filled between each conductor, with a filling density ≥85%.

4. The high-voltage conductor for subway trains with high conductivity according to claim 3, characterized in that: The conductor core (2) has a cross-sectional area of ​​50-240 square millimeters, a DC resistance of ≤0.0718Ω / km (20℃), and a conductivity of ≥102%IACS.

5. The high-voltage conductor for subway trains with high conductivity according to claim 1, characterized in that: The insulation layer (1) has a thickness of 0.5-1.5 mm and a long-term temperature resistance of ≥150℃; the moisture-proof layer (4) has a thickness of 0.3-0.8 mm and a water absorption rate of ≤0.1%; the protective layer (5) has a thickness of 0.2-0.5 mm.

6. The high-voltage conductor for subway trains with high conductivity according to claim 1, characterized in that: The insulating layer (1) is further provided with a metal shielding layer (6) and an interlocking armor layer (7). The metal shielding layer (6) is a tin-plated copper wire braided layer with a shielding efficiency ≥90dB.

7. A high-voltage conductor for subway trains with high conductivity according to claim 6, characterized in that: The interlocking armor layer (7) is an aluminum alloy strip wrapping structure with a thickness ≥1.1 mm. By using 3003 aluminum alloy strip wrapping, the tensile strength is ≥120 MPa.

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