Tensile-resistant composite cable
By employing an anti-torsion composite core, conductor, nanocomposite insulation layer, and self-healing protective sheath design in the cable, the problems of insufficient tensile strength and impact resistance of traditional cables are solved, achieving high strength, corrosion resistance, torsion resistance, and signal stability.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SICHUAN CHAODA CABLE MFG CO LTD
- Filing Date
- 2025-05-19
- Publication Date
- 2026-07-24
AI Technical Summary
Traditional cables are deficient in tensile strength, impact resistance and flexibility, and are easily damaged, especially in complex environments, making it difficult to meet the requirements of high reliability.
The anti-torsion composite core is made of high-carbon steel wire, glass fiber and Kevlar fiber in three-dimensional weaving. The conductor is made of high-strength aluminum alloy wire double spiral wound and coated with nano-level conductive ceramic. The nano-composite insulation layer has micro air channels. The shielding structure layer is made of tin-plated copper wire and aluminum-plastic composite film. The protective sleeve is made of self-healing intelligent polymer material.
It significantly improves the cable's tensile strength, torsion resistance, environmental resistance, and shielding performance, extends its service life, enhances signal transmission stability, and improves the cable's adaptability in complex environments.
Smart Images
Figure CN224554043U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of cable technology, specifically a tensile composite cable. Background Technology
[0002] In the field of modern electrical engineering, with the increasing demand for power transmission and signal transmission in various complex environments, the requirements for the comprehensive performance of cables are also becoming higher, especially in terms of tensile strength. Traditional cable structures often exhibit problems such as insufficient tensile strength, easy deformation and damage, and short service life when facing scenarios such as high-altitude installation, deep underground laying, underwater laying in marine environments, and internal wiring of large machinery, making it difficult to meet the high reliability requirements of practical applications.
[0003] Most commercially available cables rely on internal reinforcing components, such as metal wires and fiberglass, for their tensile strength. However, these reinforcing components often have limitations while providing tensile strength. For example, while a single-material metal reinforcing core has high strength, it is also heavy and prone to oxidation in corrosive environments, leading to performance degradation. On the other hand, while fiberglass reinforcing cores have certain tensile and insulation properties, their impact resistance and flexibility are poor, making them prone to breakage or delamination when the cable is subjected to external impacts or frequent bending.
[0004] To address the aforementioned issues, this application provides a tensile-resistant composite cable. Utility Model Content
[0005] The purpose of this utility model is to provide a tensile-resistant composite cable in order to solve the problems mentioned in the background art.
[0006] To achieve the above objectives, this utility model specifically adopts the following technical solution: A tensile-resistant composite cable includes an anti-torsion composite core, a conductor, a nanocomposite insulation layer, a shielding structure layer, and a protective sheath, wherein: the anti-torsion composite core is located in the middle of the protective sheath, the conductor is wound around the outside of the anti-torsion composite core, the nanocomposite insulation layer is wrapped around the outside of the conductor, and the shielding structure layer is located between the inner wall of the protective sheath and the nanocomposite insulation layer.
[0007] Furthermore, the anti-torsion composite core is woven from high-carbon steel wire, glass fiber filament and Kevlar fiber filament in a certain proportion, and the weaving structure is a three-dimensional weaving structure.
[0008] Furthermore, the conductor is made of high-strength aluminum alloy wire and is wound in a double helix manner around the outside of the anti-torsion composite core.
[0009] Furthermore, the surface of the conductor is provided with a nanoscale conductive ceramic coating.
[0010] Furthermore, the nanocomposite insulating layer is wrapped around the outside of the conductor. The nanocomposite insulating layer is composed of nano-silica, nano-alumina and a polymer substrate, and the nanocomposite insulating layer has tiny air channels inside.
[0011] Furthermore, the shielding structure layer includes a tin-plated copper wire braided shielding layer and an aluminum-plastic composite film shielding layer. The tin-plated copper wire braided shielding layer covers the outside of the nanocomposite insulating layer, and the aluminum-plastic composite film shielding layer covers the outside of the tin-plated copper wire braided shielding layer. The aluminum-plastic composite film shielding layer is composed of aluminum foil and plastic film, and the tin-plated copper wire braided shielding layer and the aluminum-plastic composite film shielding layer are tightly connected by conductive adhesive.
[0012] Furthermore, the protective case is made of a self-healing smart polymer material, and the outer surface of the protective case has a textured structure.
[0013] Furthermore, the ratio of high-carbon steel wire, glass fiber filament, and Kevlar fiber filament in the anti-torsion composite core is 1:1:1.
[0014] Compared with the prior art, the beneficial effects of this utility model are: In this design, the anti-torsion composite core is woven from a mixture of high-carbon steel wire, glass fiber, and Kevlar fiber in a specific ratio. The weaving structure is a three-dimensional structure, with the ratio of high-carbon steel wire, glass fiber, and Kevlar fiber in the anti-torsion composite core being 1:1:1. This unique combination and weaving structure gives the anti-torsion composite core multiple properties, including high strength, torsion resistance, high temperature resistance, and impact resistance. It effectively solves the performance limitations caused by the single material of existing cable tensile components, such as the large weight and easy oxidation of metal reinforcing cores, and the poor impact resistance and flexibility of glass fiber reinforcing cores.
[0015] In this design, the conductor is made of high-strength aluminum alloy wire wound in a double helix pattern on the outside of the anti-torsion composite core. The surface of the conductor is coated with a nanoscale conductive ceramic coating. The double helix winding structure gives the conductor good flexibility and tensile strength. The conductive ceramic coating not only improves the conductivity of the conductor, but also enhances its wear resistance and corrosion resistance, thereby extending the service life of the cable.
[0016] In this design, a nanocomposite insulating layer is wrapped around the outside of the conductor. It is composed of nano-silica, nano-alumina, and a polymer substrate, and has tiny air channels inside. This combination of materials significantly improves the insulation performance, heat resistance, and mechanical strength of the insulating layer. At the same time, the tiny air channels effectively reduce the dielectric constant of the insulating layer, improve the insulation performance and signal transmission speed, and also play a role in heat dissipation.
[0017] The shielding structure in this solution includes a tinned copper wire braided shielding layer and an aluminum-plastic composite film shielding layer. The braiding density of the tinned copper wire braided shielding layer reaches over 90%, and the aluminum-plastic composite film shielding layer is composed of aluminum foil and plastic film, which are tightly connected by conductive adhesive. This double-layer shielding structure design effectively improves the electromagnetic shielding performance of the cable, prevents external electromagnetic interference from affecting the internal signal, and also prevents leakage of the internal electromagnetic field, ensuring the stability and accuracy of signal transmission.
[0018] In this solution, the protective sleeve is made of self-healing intelligent polymer material with a special textured structure on the outer surface. The self-healing intelligent polymer material can automatically repair external damage to the sheath, extending the service life of the cable. At the same time, the textured structure on the outer surface increases the friction with the surrounding environment, preventing the cable from slipping during laying and use, and also has a certain heat dissipation function. Attached Figure Description
[0019] Figure 1 This is a three-dimensional structural diagram of the present invention; Figure 2 This utility model Figure 1 A partial view of a three-dimensional sectional view; Figure 3 This is a three-dimensional structural diagram of another state of the present utility model; Figure 4 This is an exploded view of the present invention.
[0020] In the diagram: 1. Anti-torsion composite core; 2. Conductor; 3. Nanocomposite insulation layer; 4. Shielding structure layer; 41. Tinned copper wire braided shielding layer; 42. Aluminum-plastic composite film shielding layer; 5. Protective sleeve. Detailed Implementation
[0021] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings.
[0022] This application provides a tensile-strength composite cable, primarily addressing the issue that the tensile strength of most commonly available cables relies on internal reinforcing components such as metal wires and fiberglass. However, these reinforcing components, while providing tensile strength, often have limitations. For example, while a single-material metal reinforcing core has high strength, it is heavy and prone to oxidation in corrosive environments, leading to performance degradation. While a fiberglass reinforcing core possesses certain tensile and insulation properties, its impact resistance and flexibility are poor, making it susceptible to breakage or delamination when subjected to external impacts or frequent bending. The following technical solution is provided, which will be discussed in conjunction with… Figures 1-4 Please provide a detailed explanation: A tensile-resistant composite cable mainly includes an anti-torsion composite core 1, a conductor 2, a nanocomposite insulation layer 3, a shielding structure layer 4, and a protective sleeve 5, wherein: the anti-torsion composite core 1 is located in the middle of the protective sleeve 5, the conductor 2 is wound around the outside of the anti-torsion composite core 1, the nanocomposite insulation layer 3 is wrapped around the outside of the conductor 2, and the shielding structure layer 4 is located between the inner wall of the protective sleeve 5 and the nanocomposite insulation layer 3.
[0023] This design significantly improves the cable's tensile strength, torsional strength, environmental resistance, and shielding, meeting the needs of use in complex environments.
[0024] In the fabrication of this tensile composite cable, the preparation of the anti-torsion composite core 1 is particularly crucial. Specifically, the anti-torsion composite core 1 is woven from a mixture of high-carbon steel wire, glass fiber filaments, and Kevlar fiber filaments in a certain proportion, and the weaving structure is a three-dimensional braided structure. During the weaving process, the proportion of high-carbon steel wire, glass fiber filaments, and Kevlar fiber filaments in the anti-torsion composite core 1 is strictly controlled at 1:1:1. This design allows the anti-torsion composite core 1 to fully utilize the advantages of each material, including the high strength of the high-carbon steel wire, the good insulation and high-temperature resistance of the glass fiber filaments, and so on. The combination of the excellent impact resistance and toughness of Kevlar fiber gives the anti-torsion composite core 1 outstanding tensile, torsional and impact resistance properties, effectively solving the performance deficiencies of traditional cable reinforcement components caused by single materials, such as the heavy weight and easy oxidation of metal reinforcement cores, and the poor impact resistance and flexibility of glass fiber reinforcement cores. At the same time, the three-dimensional braided structure further enhances the overall strength and rigidity of the anti-torsion composite core 1, ensuring that it can stably provide support and protection in complex operating environments, laying a solid foundation for the subsequent cable assembly and use.
[0025] Furthermore, the configuration of conductor 2 is also crucial in the fabrication of this tensile composite cable. Conductor 2 is made of high-strength aluminum alloy wire and is wound around the outside of the anti-torsion composite core 1 in a double helix manner. The high-strength aluminum alloy wire not only has excellent conductivity but also high mechanical strength and tensile strength, which can effectively improve the overall strength and durability of the cable. The double helix winding method gives conductor 2 better flexibility and tensile strength, which can effectively disperse stress when the cable is subjected to external force for stretching or bending, reducing the risk of conductor 2 breakage, thereby significantly improving the service life and reliability of the cable. In addition, the surface of conductor 2 is coated with a nanoscale conductive ceramic coating. This conductive ceramic coating not only further improves the conductivity of conductor 2, reduces resistance, and reduces losses during power transmission, but also enhances the wear resistance and corrosion resistance of conductor 2. In complex operating environments, conductor 2 can effectively resist the erosion of external chemicals and ensure the long-term stable operation of the cable. This design cleverly solves the shortcomings of traditional cable conductor 2 in terms of mechanical and electrical performance, and provides a strong guarantee for the efficient and stable operation of the cable in various harsh environments.
[0026] Furthermore, the nanocomposite insulation layer 3 is wrapped around the outside of the conductor 2. The nanocomposite insulation layer 3 is composed of nano-silica, nano-alumina and a polymer substrate. The addition of nano-silica and nano-alumina significantly improves the insulation performance, heat resistance and mechanical strength of the nanocomposite insulation layer 3, while retaining good flexibility. The nanocomposite insulation layer 3 has tiny air channels inside. These tiny air channels can effectively reduce the dielectric constant of the nanocomposite insulation layer 3, thereby improving its insulation performance and signal transmission speed. It also has a certain heat dissipation effect, which helps the cable maintain a stable operating temperature during operation.
[0027] During the manufacturing process, conductor 2 is first wound around the outside of anti-torsion composite core 1 according to the design requirements. Then, using specialized equipment, an insulating material composed of nano-silica, nano-alumina, and polymer substrate is uniformly wrapped around conductor 2. By precisely controlling the process parameters, the thickness of the nano-composite insulation layer 3 is ensured to be uniform and the internal structure is formed with uniformly distributed micro air channels. This design not only enables the nano-composite insulation layer 3 to effectively isolate conductor 2 from the external environment and prevent conductor 2 from being corroded and interfered with by external substances, but also enhances the insulation performance and heat dissipation effect through the micro air channels, ensuring that the cable has good stability and reliability during long-term operation.
[0028] In this embodiment, the shielding structure layer 4 includes a tin-plated copper wire braided shielding layer 41 and an aluminum-plastic composite film shielding layer 42. The tin-plated copper wire braided shielding layer 41 covers the outside of the nanocomposite insulation layer 3. By utilizing the excellent conductivity of the tin-plated copper wire and the density of the braided structure, a highly efficient electromagnetic shielding layer is formed, which effectively blocks external electromagnetic interference and ensures the stability of signal transmission inside the cable. Its braiding density reaches more than 90%, thereby achieving excellent shielding effect. However, the aluminum-plastic composite film shielding layer 42 is wrapped around the outside of the tinned copper wire braided shielding layer 41. The aluminum-plastic composite film shielding layer 42 is made of aluminum foil and plastic film, which further enhances the shielding performance. The plastic film improves environmental adaptability and plays a role in moisture-proofing and waterproofing, providing more reliable protection for the cable. Specifically, the tin-plated copper wire braided shielding layer 41 and the aluminum-plastic composite film shielding layer 42 are tightly connected with conductive adhesive to ensure good electrical contact between the two shielding layers, enhance the integrity and continuity of the shielding structure, and effectively prevent electromagnetic interference leakage. This double-layer shielding structure cleverly solves the problem of poor shielding effect in traditional cables, significantly improves the electromagnetic compatibility of the cable, and makes it suitable for complex environments with high requirements for signal transmission quality.
[0029] It should be noted that in the manufacturing process of this tensile composite cable, the protective sleeve 5 provides the final protective barrier for the cable. The protective sleeve 5 is made of a self-healing intelligent polymer material, specifically a polyethylene oxide-based self-healing material. This material contains microcapsule-type self-healing agents. When the cable experiences minor scratches or cracks on the sheath surface due to external forces during use, the microcapsules rupture and release the self-healing agent. This agent fills the damaged area and quickly cures, effectively preventing harmful substances such as moisture, oxygen, and salt spray from penetrating the cable's interior. This protects the internal structure from corrosion and damage, significantly extending the cable's service life and reducing maintenance costs. The protective sleeve 5 is located on the outermost layer of the cable, and its outer surface has a special textured structure. This textured structure increases the friction between the sheath and the surrounding environment, preventing the cable from slipping during laying and use, ensuring the cable's installation stability. Simultaneously, the textured structure also provides some heat dissipation, helping the cable maintain a suitable operating temperature during operation. Through this design, the protective sleeve 5 not only significantly improves the cable's mechanical protection performance but also enhances its adaptability and reliability in complex environments.
[0030] 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 tensile-resistant composite cable, characterized in that, It includes an anti-torsion composite core (1), a conductor (2), a nanocomposite insulation layer (3), a shielding structure layer (4), and a protective sleeve (5), wherein: the anti-torsion composite core (1) is located in the middle of the protective sleeve (5), the conductor (2) is wrapped around the outside of the anti-torsion composite core (1), the nanocomposite insulation layer (3) is wrapped around the outside of the conductor (2), and the shielding structure layer (4) is located between the inner wall of the protective sleeve (5) and the nanocomposite insulation layer (3).
2. The tensile composite cable according to claim 1, characterized in that: The conductor (2) is made of high-strength aluminum alloy wire and is wound around the outside of the anti-torsion composite core (1) in a double helix manner.
3. The tensile composite cable according to claim 1, characterized in that: The surface of the conductor (2) is provided with a nanoscale conductive ceramic coating.
4. The tensile composite cable according to claim 1, characterized in that: The nanocomposite insulating layer (3) is wrapped around the outside of the conductor (2).
5. The tensile composite cable according to claim 1, characterized in that: The shielding structure layer (4) includes a tin-plated copper wire braided shielding layer (41) and an aluminum-plastic composite film shielding layer (42). The tin-plated copper wire braided shielding layer (41) covers the outside of the nanocomposite insulating layer (3), and the aluminum-plastic composite film shielding layer (42) covers the outside of the tin-plated copper wire braided shielding layer (41). The aluminum-plastic composite film shielding layer (42) is composed of aluminum foil and plastic film, and the tin-plated copper wire braided shielding layer (41) and the aluminum-plastic composite film shielding layer (42) are tightly connected by conductive adhesive.
6. The tensile composite cable according to claim 1, characterized in that: The protective sleeve (5) is made of self-healing intelligent polymer material, and the outer surface of the protective sleeve (5) has a textured structure.