An ultra-soft reel cable

Abstract

This utility model discloses an ultra-flexible reel cable, relating to the field of cable technology, which solves the problems of insufficient weight and flexibility, as well as poor waterproof performance, of existing reel cables. It includes a cable core structure and a sheath wrapped around the cable core structure. The sheath includes an outer sheath, an inner sheath, and a reinforcing layer. The reinforcing layer is disposed between the outer and inner sheaths. A waterproof layer, which is a water-blocking tape, is disposed between the inner and reinforcing layers and is wrapped around the outer sheath. It also includes a filler layer disposed between the sheath and the cable core structure. The filler layer includes a buffer layer and a reinforcing layer, with the reinforcing layer disposed outside the cable core structure. The design of this utility model cable achieves lightweight, high flexibility, excellent waterproof performance, and improved overall performance while ensuring conductivity, making it suitable for various complex environments and bending situations.

Description

Technical Field

[0001] This utility model belongs to the field of cable technology, and in particular relates to an ultra-flexible reel cable. Background Technology

[0002] Ultra-flexible reel cables are high-performance cables designed for scenarios involving frequent movement, bending, and winding. They possess excellent flexibility and durability and are primarily used in: ① Heavy-duty mobile equipment, such as port machinery (gantry cranes, container cranes) and mining equipment (tunneling machines, electric loaders); ② Automated production lines, conveyors, winches, and other applications requiring frequent power supply; ③ Special environments, such as corrosive environments like garbage cranes and sludge removal machines, as well as occasions requiring flexible wiring, such as stage lighting.

[0003] Currently, existing reel cables have the following main shortcomings:

[0004] Traditional cables typically use ordinary rubber or plastic for their sheaths. While these materials offer some abrasion resistance, their poor flexibility makes them prone to breakage or deformation when used in bending situations. Furthermore, traditional cables often use pure copper conductors, which, although offering excellent conductivity, are heavy, increasing the overall weight of the cable and making installation and use inconvenient, especially in situations requiring frequent movement or where space is limited. The bulkiness of traditional cables becomes a major drawback. Moreover, the waterproofing design of existing cables is relatively simple, usually relying solely on the waterproofing of the sheath material itself, lacking a dedicated waterproof layer. When cables are exposed to humid environments for extended periods or experience water seepage, moisture can easily diffuse longitudinally along the cable to the gaps between the cores, causing the cores to become damp. This can lead to short circuits, decreased insulation performance, and other problems, severely impacting the cable's safety and lifespan.

[0005] In summary, existing technologies for reel cables suffer from insufficient weight and flexibility, as well as poor waterproofing performance. Utility Model Content

[0006] This invention provides an ultra-flexible reel cable that can solve the problems of insufficient weight and flexibility, as well as poor waterproof performance, of existing reel cables.

[0007] To achieve the above objectives, according to an embodiment of the first aspect of this utility model, an ultra-flexible drum cable is provided, comprising a cable core structure and a sheath wrapped around the cable core structure; the sheath comprises an outer sheath, an inner sheath, and a reinforcing layer, the reinforcing layer being disposed between the outer sheath and the inner sheath, and a waterproof layer being disposed between the inner sheath and the reinforcing layer, the waterproof layer being a water-blocking tape wrapped around the outside of the outer sheath;

[0008] Also includes:

[0009] A filler layer is disposed between the sheath and the cable core structure. The filler layer includes a buffer layer and a reinforcing layer. The reinforcing layer is disposed outside the cable core structure. The gap between the reinforcing layer and each conductor is filled with polyurethane material. The buffer layer is disposed outside the reinforcing layer.

[0010] A further improvement is that the cable core structure includes several arrayed conductors and an insulating sleeve wrapped around each conductor.

[0011] A further improvement is that the conductor is made of either copper-clad aluminum or copper-clad steel, a design that reduces weight and improves flexibility while ensuring conductivity.

[0012] A further improvement is that the outer surface of the sheath is provided with a layer of fluorinated silane modified material, and the fluorinated silane modified material is sprayed onto the outer surface of the outer protective layer.

[0013] A further improvement is that the sheath is made of one of the following materials: thermoplastic elastomer, polyurethane, or polyvinyl chloride.

[0014] A further improvement is that the reinforcing layer is composed of a composite of metal wires and aramid fibers.

[0015] A further improvement is that the reinforcing layer is a layer of spiral aramid fiber, which wraps the entire cable core structure.

[0016] A further improvement is that the buffer layer is a layer of silicone foam material.

[0017] Compared with the prior art, the beneficial effects of this utility model are:

[0018] (1) This utility model uses a material of thermoplastic elastomer, polyurethane or polyvinyl chloride for the cable sheath, which has good flexibility and wear resistance; and uses copper-clad aluminum or copper-clad steel conductors in the cable core structure, which not only ensures conductivity, but also reduces the weight of the cable and improves flexibility, making it more suitable for bending occasions.

[0019] (2) This utility model sets the sheath as an outer sheath, an inner sheath, and a reinforcing layer. A waterproof layer is set between the inner sheath and the reinforcing layer. The waterproof layer is a water-blocking tape wrapped around the outside of the outer sheath. The water-blocking tape is chosen as the waterproof layer because it can expand to form a gel when it comes into contact with water, thus preventing water from spreading longitudinally along the cable and into the gaps between the cable cores. This greatly improves the waterproof performance of the cable. The outer sheath provides external protection, the inner sheath enhances internal stability, and the reinforcing layer is made of a composite of metal wire and aramid fiber. This design enables the cable to have excellent high temperature resistance and insulation performance, while also giving it high strength and high corrosion resistance, further improving the overall performance of the cable.

[0020] (3) This utility model provides a filling layer between the sheath and the core structure. The filling layer includes a buffer layer and a reinforcing layer. The reinforcing layer is located outside the core structure. The gap between the reinforcing layer and each conductor is filled with polyurethane material. The buffer layer is located outside the reinforcing layer. The reinforcing layer is a layer of spiral aramid fiber. The spiral aramid fiber wraps the entire core structure to enhance the tensile strength and overall stability of the core structure. The buffer layer is a layer of silicone foam material, which allows the cable to maintain better buffer performance in a humid environment. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall cable structure of this utility model;

[0022] Figure 2 This is a schematic diagram of the overall structure of the cable cross-section of this utility model;

[0023] Figure 3 This is a partial structural diagram of the cable cross-section of this utility model.

[0024] Marked in the image:

[0025] 1. Cable core structure; 11. Insulation sleeve; 12. Conductor; 2. Sheath; 21. Outer sheath; 22. Inner sheath; 23. Reinforcing layer; 24. Waterproof layer; 3. Filling layer; 31. Buffer layer; 32. Reinforcing layer; 4. Polyurethane material. Detailed Implementation

[0026] The technical solution of this utility model will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0027] like Figures 1 to 3 As shown, an ultra-flexible reel cable includes a core structure 1 and a sheath 2 wrapped around the core structure 1.

[0028] Specifically, the cable core structure 1 includes several arrayed conductors 12 and an insulating sleeve 11 wrapped around each conductor 12. The conductors 12 are either copper-clad aluminum conductors or copper-clad steel conductors. This design can reduce weight and improve flexibility while ensuring conductivity.

[0029] The sheath 2 includes an outer sheath 21, an inner sheath 22, and a reinforcing layer 23. The reinforcing layer 23 is disposed between the outer sheath 21 and the inner sheath 22. A waterproof layer 24 is disposed between the inner sheath 22 and the reinforcing layer 23. The waterproof layer 24 is a water-blocking tape wrapped around the outside of the outer sheath 21. The water-blocking tape is chosen as the waterproof layer 24 because the water-blocking tape itself can expand to form a gel when it comes into contact with water, and prevent water from spreading longitudinally along the cable into the gaps between the cable cores inside the cable, which greatly improves the waterproof performance of the cable.

[0030] Specifically, the outer sheath 2 is provided with a layer of fluorinated silane modified material. The fluorinated silane modified material is sprayed on the outer sheath 21. This design can reduce moisture adhesion and prevent water ingress from damaging the cable. It is suitable for shallow water or humid environments.

[0031] It should be noted that the sheath 2 is made of one of the following materials: thermoplastic elastomer (TPE), polyurethane (TPU), or polyvinyl chloride (PVC). In this embodiment, thermoplastic elastomer (TPE) is used as an example. This design can improve the flexibility of the cable, thus making it suitable for bending applications.

[0032] Specifically, the reinforcing layer 23 is composed of metal wire and aramid fiber. This design enables the cable to have excellent high temperature resistance and insulation performance, while also giving the cable high strength and high corrosion resistance, thereby further improving the overall performance of the cable.

[0033] like Figure 2 and Figure 3 As shown in this embodiment, another implementation scheme is also provided, as detailed below:

[0034] It includes a filling layer 3, which is disposed between the sheath 2 and the cable core structure 1. The filling layer 3 includes a buffer layer 31 and a reinforcing layer 32. The reinforcing layer 32 is disposed outside the cable core structure 1. The gap between the reinforcing layer 32 and each conductor 12 is filled with polyurethane material 4. The buffer layer 31 is disposed outside the reinforcing layer 32.

[0035] It should be noted that the reinforcing layer 32 is a layer of spiral aramid fiber. The spiral aramid fiber wraps the entire cable core structure 1 to enhance the tensile strength and overall stability of the cable core structure 1.

[0036] Specifically, the buffer layer 31 is a layer of silicone foam material, which is wrapped around the outside of the reinforcing layer 32. Due to the characteristics of silicone foam material, namely temperature resistance from -60℃ to +250℃, tear strength of 20kN / m, and water absorption rate of closed-cell structure <0.1%, the cable can still maintain excellent buffer performance in humid environments.

[0037] like Figures 1 to 3As shown in this embodiment, it should also be noted that the actual dimensions of each component in the application document are selected and installed according to the actual needs on site. Additionally, it should be noted that this ultra-flexible drum cable is manufactured using existing processes. This application document only addresses the shortcomings of existing drum cables, such as insufficient weight and flexibility, and poor waterproof performance, and does not involve other aspects. The working principle of this ultra-flexible drum cable is described below:

[0038] When this new solution is used, the cable sheath is made of one of the following materials: thermoplastic elastomer (TPE), polyurethane (TPU), or polyvinyl chloride (PVC), which provides good flexibility and abrasion resistance. The conductors in the cable core structure are made of copper-clad aluminum or copper-clad steel, which ensures conductivity, reduces cable weight, and improves flexibility, making it more suitable for bending applications.

[0039] By configuring the sheath 2 as an outer sheath 21, an inner sheath 22, and a reinforcing layer 23, and placing a waterproof layer 24 between the inner sheath 22 and the reinforcing layer 23, the waterproof layer 24 is a water-blocking tape wrapped around the outside of the outer sheath 21. The water-blocking tape is chosen as the waterproof layer 24 because its properties allow it to expand upon contact with water to form a gel, preventing moisture from diffusing longitudinally into the gaps between the cable cores, thus significantly improving the cable's waterproof performance. With the outer sheath 21 providing external protection, the inner sheath 22 enhancing internal stability, and the reinforcing layer 23 being a composite of metal wire and aramid fiber, this design enables the cable to possess excellent high-temperature resistance and insulation performance, while also exhibiting high strength and high corrosion resistance, further improving the cable's overall performance.

[0040] In addition, a filling layer 3 is provided between the sheath 2 and the cable core structure 1. The filling layer 3 includes a buffer layer 31 and a reinforcing layer 32. The reinforcing layer 32 is provided outside the cable core structure 1. The gap between the reinforcing layer 32 and each conductor 12 is filled with polyurethane material 4. The buffer layer 31 is provided outside the reinforcing layer 32. The reinforcing layer 32 is a layer of spiral aramid fiber. The spiral aramid fiber wraps the entire cable core structure 1 to enhance the tensile strength and overall stability of the cable core structure 1. The buffer layer 31 is a layer of silicone foam material, which allows the cable to maintain better buffering performance in a humid environment.

[0041] The above embodiments are only used to illustrate the technical methods of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical methods of this utility model without departing from the spirit and scope of the technical methods of this utility model.

Claims

1. An ultra-flexible reel cable, comprising a core structure (1) and a sheath (2) wrapped around the core structure (1); characterized in that, The sheath (2) includes an outer sheath (21), an inner sheath (22), and a reinforcing layer (23). The reinforcing layer (23) is disposed between the outer sheath (21) and the inner sheath (22). A waterproof layer (24) is disposed between the inner sheath (22) and the reinforcing layer (23). The waterproof layer (24) is a water-blocking strip wrapped around the outside of the outer sheath (21). Also includes: A filling layer (3) is disposed between the sheath (2) and the core structure (1). The filling layer (3) includes a buffer layer (31) and a reinforcing layer (32). The reinforcing layer (32) is disposed outside the core structure (1). The gap between the reinforcing layer (32) and each conductor (12) is filled with polyurethane material (4). The buffer layer (31) is disposed outside the reinforcing layer (32).

2. The ultra-flexible reel cable according to claim 1, characterized in that, The cable core structure (1) includes a number of arrayed conductors (12) and an insulating sleeve (11) wrapped around each conductor (12).

3. The ultra-flexible reel cable according to claim 2, characterized in that, The conductor (12) is made of either copper-clad aluminum conductor or copper-clad steel conductor. This design can reduce weight and improve flexibility while ensuring conductivity.

4. The ultra-flexible reel cable according to claim 1, characterized in that, The outer side of the sheath (2) is provided with a layer of fluorinated silane modified material, and the fluorinated silane modified material is sprayed onto the outer side of the outer protective layer (21).

5. The ultra-flexible reel cable according to claim 4, characterized in that, The sheath (2) is made of one of the following materials: thermoplastic elastomer, polyurethane, or polyvinyl chloride.

6. The ultra-flexible reel cable according to claim 1, characterized in that, The reinforcing layer (23) is composed of metal wire and aramid fiber.

7. The ultra-flexible reel cable according to claim 1, characterized in that, The reinforcing layer (32) is a layer of spiral aramid fiber, which wraps the entire cable core structure (1).

8. The ultra-flexible reel cable according to claim 1, characterized in that, The buffer layer (31) is a layer of silicone foam material.

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