Highly flexible tensile resistant shielded power cable

Abstract

This utility model discloses a highly flexible, tensile-resistant shielded power cable, comprising a conductor layer, a fastening layer, an insulation layer, a shielding layer, and a sheath layer arranged coaxially from the inside out. The fastening layer is a heat-shrinkable braided tubing, which, after heat shrinking, forms a tight, compressed fit with the outer surface of the conductor layer, significantly improving the cable's tensile strength. The shielding layer is a heat-shrinkable tube with a metal wire braided mesh layer. Before heat shrinking, its original inner diameter D1 and the outer diameter D2 of the insulation layer satisfy 1.1 ≤ D1 / D2 ≤ 1.2; after heat shrinking, its final inner diameter D1' and D2 satisfy 1.02 ≤ D1' / D2 ≤ 1.08, ensuring a tight electromagnetic shielding contact between the shielding layer and the outer surface of the insulation layer. This utility model, through its unique interlayer heat-shrinkable fastening and shielding structure, achieves a balance between excellent flexibility, small diameter, high tensile strength, and stable shielding, making it particularly suitable for scenarios requiring frequent bending and small-area wiring, such as stage equipment and automotive wiring harnesses.

Description

Technical Field

[0001] This utility model relates to the field of power cable technology, specifically to a highly flexible, high tensile strength power cable with an integrated shielding structure that is particularly suitable for scenarios requiring frequent bending and small-scale wiring. Background Technology

[0002] In the wiring of stage equipment, automotive interiors, and home appliances, extremely high requirements are placed on power cables. These scenarios typically require cables to have the following characteristics: first, small diameter to save limited space; second, good flexibility to adapt to frequent bending and movement; third, high tensile strength to prevent damage during the pulling and stretching of the cabling; fourth, good electromagnetic shielding performance to prevent internal signals from interfering with external equipment or external electromagnetic noise from affecting the signal transmission inside the cable; and fifth, high manufacturing efficiency to meet the needs of rapid production.

[0003] Currently, traditional cables on the market often fail to meet all of the above requirements simultaneously. For example, to improve tensile strength, armor layers or reinforcing ribs are usually added to the structure, but this leads to an increase in cable diameter and a decrease in flexibility. Shielding layers often use copper wire braiding or aluminum foil wrapping, which are complex processes and do not bond tightly enough to the insulation layer, easily creating gaps under frequent bending and resulting in reduced shielding effectiveness. Furthermore, traditional cable manufacturing processes involve numerous steps, and fixing the layers requires adhesives or complex molding processes, limiting production efficiency.

[0004] Therefore, there is an urgent need for a new type of cable structure that can fundamentally solve the above contradictions and achieve a perfect balance between small diameter, high flexibility, high tensile strength, efficient shielding, and rapid manufacturing. Utility Model Content

[0005] In view of the shortcomings of the existing technology, this utility model aims to provide a highly flexible tensile shielded power cable to solve the technical problems that traditional cables cannot simultaneously achieve small diameter, high flexibility, high tensile strength, stable shielding effectiveness and rapid manufacturing.

[0006] To solve the above-mentioned technical problems, this utility model provides the following technical solution: a highly flexible tensile shielded power cable, comprising a conductor layer, a fastening layer, an insulation layer, a shielding layer and a sheath layer arranged coaxially from the inside to the outside; the fastening layer forms a tight compression and bonding structure with the outer surface of the conductor layer after being heated and shrinking, and the shielding layer forms a tight electromagnetic shielding contact with the outer surface of the insulation layer after being heated and shrinking.

[0007] As a preferred embodiment of the high-flexibility tensile-strength shielded power cable of this utility model, the conductor layer is composed of multiple stranded metal wires, such as soft copper wire or aluminum wire, and the conductor cross-sectional area is 4-25mm².

[0008] As a preferred embodiment of the high-flexibility tensile shielded power cable of this utility model, the fastening layer is a heat-shrinkable braided sleeve, the braiding density of the braided sleeve is ≥80%, and the wall thickness of the fastening layer after heat shrinkage is 0.2-0.8mm.

[0009] As a preferred embodiment of the high-flexibility tensile-strength shielded power cable of this utility model, the shielding layer is a heat-shrinkable tube with electromagnetic shielding function, and the shielding layer structure includes an outer heat-shrinkable plastic layer and an inner metal wire braided mesh layer.

[0010] As a preferred embodiment of the high-flexibility tensile-strength shielded power cable of this utility model, the metal wire braided mesh layer is made of tin-plated copper wire or copper wire.

[0011] As a preferred embodiment of the high-flexibility tensile-strength shielded power cable of this utility model, the original inner diameter D1 of the shielding layer before heat shrinking and the outer diameter D2 of the insulation layer satisfy: 1.1≤D1 / D2≤1.2; the final inner diameter D1' of the shielding layer after heat shrinking and the outer diameter D2 of the insulation layer satisfy: 1.02≤D1' / D2≤1.08.

[0012] As a preferred embodiment of the high-flexibility tensile-strength shielded power cable of this utility model, the wall thickness of the shielding layer after heat shrinking is 0.2mm-0.6mm.

[0013] In a preferred embodiment of the high-flexibility tensile-strength shielded power cable of this utility model, the thickness of the sheath layer is 2-5mm.

[0014] Compared with the prior art, the present invention has the following significant advantages: (1) Small diameter and compact structure: By using heat-shrinkable fastening layers to replace traditional fillers and binding structures, and using heat-shrinkable shielding layers to replace loose braided shielding, the gaps between layers are greatly compressed, so that the cable has a smaller outer diameter under the same conductor cross-sectional area, saving more installation space.

[0015] (2) High tensile strength: After the fastening layer shrinks due to heat, it forms a strong radial compressive force on the conductor layer, tightly binding multiple soft copper wires into a whole, effectively suppressing the relative slippage between conductor filaments when under tension, thus combining the flexibility of the conductor itself with the high tensile strength of the cable as a whole.

[0016] (3) Excellent flexibility: The Type 5 structure of the conductor layer, the flexible materials of the fastening layer and the insulation layer, and the thin-walled shielding layer design together give the cable excellent bending performance, enabling it to withstand frequent bending without fatigue damage.

[0017] (4) Stable and reliable shielding performance: The shielding layer is tightly bonded to the insulation layer through heat shrink technology, and there is no gap between the metal shielding mesh and the insulation layer. Even under dynamic bending working conditions, it can maintain stable shielding contact, and the shielding performance will not decrease due to changes in cable shape, effectively improving the anti-electromagnetic interference capability.

[0018] (5) Suitable for rapid manufacturing: The cable structure of this utility model is very suitable for modular and assembly line production. Both the fastening layer and the shielding layer can be installed and fixed by simple sleeve and heating steps. The process is simple and does not require complicated vulcanization, braiding or wrapping equipment, which greatly improves production efficiency and is especially suitable for rapid delivery of large-scale orders. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the cross-sectional structure of a highly flexible tensile shielded power cable. Figure 2 This is a schematic diagram of the shielding layer structure of a highly flexible, tensile-resistant shielded power cable. In the diagram: Conductor layer 1, Fastening layer 2, Insulating layer 3, Shielding layer 4, Sheath layer 5, Heat-shrinkable plastic layer 41, Metal wire braided mesh layer 42. Detailed Implementation

[0021] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings.

[0022] Many specific details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0023] Secondly, the term "an embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that excludes other embodiments.

[0024] Example 1: 10mm² Highly Flexible Cable for Stage Equipment like Figure 1 As shown, the core of this utility model is the design and coordination of a five-layer structure, especially the structure of the fastening layer and the shielding layer achieved through heat shrink technology.

[0025] First, conductor layer 1 is prepared. Multiple soft copper wires with a diameter of 0.15 mm are selected and precisely stranded according to the requirements for Class 5 conductors in GB / T3956 to form a conductor with a cross-sectional area of ​​10 mm². This stranding structure gives the cable basic flexibility, laying the foundation for subsequent applications involving frequent bending.

[0026] Next, install the fastening layer 2. A 3.5mm inner diameter PET heat-shrinkable braided sleeve with a braiding density of 85% is selected as the fastening layer. It is fitted over the conductor layer, leaving an assembly gap between the sleeve and the conductor. Then, a hot air gun set to 120℃ is used to uniformly heat it along the axial direction. Under heat, the fastening layer contracts radially, its braided structure tightens, and it forms a tight, compressed fit with the outer surface of the conductor layer. This structure produces two key effects: first, it generates a strong radial compressive force on the internal conductor strands, securing multiple soft copper wires into a single unit, effectively improving the cable's tensile strength and suppressing relative slippage between individual wires during stretching; second, the fastening layer itself is thin, with a wall thickness of approximately 0.5mm after heat shrinking, significantly reducing the cable's radial dimension compared to traditional fillers and binding structures.

[0027] Next, the insulation layer 3 is extruded. A layer of silane-crosslinked ethylene propylene rubber is uniformly extruded onto the outer surface of the already tightened layer using a 65-type extruder to form the insulation layer. The extrusion process utilizes the viscous flow properties of the silane-crosslinked ethylene propylene rubber in its highly elastic state, ensuring a firm bond with the outer surface of the tightened layer. After cooling, it forms an integrated, flexible insulation structure. The outer diameter D2 of the insulation layer is controlled at 5.0 mm. As cable insulation, ethylene propylene rubber outperforms crosslinked polyethylene in terms of temperature resistance, aging performance, and flexibility. Traditional ethylene propylene rubber is crosslinked using peroxides, a method that may release byproducts and impact the environment. Silane-crosslinked ethylene propylene rubber addresses this issue.

[0028] Finally, install and activate shielding layer 4. See also Figure 2The shielding layer is a composite heat-shrinkable tubing, comprising an outer polyolefin heat-shrinkable plastic layer 41 and an inner tin-plated copper wire braided mesh layer 42. The outer diameter D2 of the insulation layer is measured to be 5.0 mm. Based on this, a shielding tube with an original inner diameter D1 = 5.5 mm before heat shrinking (satisfying D1 / D2 = 1.1) is selected. It is then fitted over the insulation layer. A hot air gun is used to uniformly heat it at 135°C. The shielding tube shrinks radially uniformly after heating until its final inner diameter D1' shrinks to approximately 5.15 mm (satisfying D1' / D2 = 1.03), at which point the wall thickness of the shielding layer after heat shrinking is approximately 0.35 mm. During this process, the shielding layer forms a tight electromagnetic shielding contact with the outer surface of the insulation layer after heat shrinking. Specifically, the inner tin-plated copper wire braided mesh layer is tightly and uniformly pressed onto the surface of the insulation layer, eliminating gaps that may occur due to bending in traditional braided shielding, achieving stable electromagnetic shielding with no dead angles (360°). The outer heat-shrinkable plastic layer provides structural retention and a certain tensile strength for shielding the contact.

[0029] Finally, the outermost sheath layer 5 is extruded. A 3.0mm thick layer of PE material is extruded onto the outer surface of the already tightly wrapped shielding layer using an extruder, forming the outermost sheath layer. The sheath provides abrasion resistance, weather resistance, and a certain degree of flame retardancy protection for the internal structure of the cable.

[0030] The cable produced through the above steps, after testing, has an outer diameter approximately 18% smaller and a weight reduction of 20% compared to traditional shielded cables of the same specifications. In tensile testing, due to the combined effect of the conductor layer, fastening layer, and shielding layer, its tensile strength is increased by more than 35% compared to similar cables without this structure. After undergoing 3000 repeated bending tests, the shielding effectiveness decreases by less than 3dB, fully meeting the requirements for cabling during frequent movement of stage equipment.

[0031] Example 2: 6mm² ultra-flexible cable suitable for automotive wiring harnesses This embodiment has the same structure as Embodiment 1, the main difference being that the parameters are adapted to automotive wiring harness applications with smaller cross-sections.

[0032] Conductor layer: made of 0.12mm soft copper wire stranded together, with a cross-sectional area of ​​6mm².

[0033] Fastening layer: A thinner nylon heat-shrinkable braided sleeve is selected, with an inner diameter of 2.2mm before heat shrinking and a braiding density of ≥80%. After heat shrinking, the wall thickness is about 0.3mm, forming a strong compression fit with the conductor layer, effectively resisting vibration stress in the engine compartment.

[0034] Insulation layer: The outer diameter D2 of the silane cross-linked ethylene propylene rubber insulation layer is controlled at 3.6 mm.

[0035] Shielding layer: A thin-walled shielded heat-shrink tubing with an original inner diameter D1 = 4.0 mm (D1 / D2≈1.11) before heat shrinking is selected. After heat shrinking, the final inner diameter D1' is 3.7 mm (D1' / D2≈1.028), and the shielding layer wall thickness is approximately 0.25 mm. The tight electromagnetic shielding contact effectively suppresses high-frequency interference in automotive circuits.

[0036] Sheath layer: Made of PE material, with a thickness of 2.5mm.

[0037] This structure cable exhibits excellent flexibility, with a minimum bending radius of up to 3 times the cable's outer diameter, making it ideal for wiring in confined automotive spaces. At the same time, its stable shielding performance ensures the reliable operation of in-vehicle electronic equipment.

[0038] In summary, this utility model integrates the advantages of high flexibility, high tensile strength, small diameter, and high-efficiency shielding in a single cable through the extrusion bonding structure formed by the heat shrinking of the fastening layer and the conductor layer, and the tight electromagnetic shielding contact formed by the heat shrinking of the shielding layer and the insulation layer. Furthermore, it achieves the goal of rapid and efficient manufacturing through an easily implemented heat shrinking process.

[0039] It should be noted that the above embodiments are only used to illustrate the technical solution 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 solution of this utility model without departing from the spirit and scope of the technical solution of this utility model, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. A highly flexible tensile-strength shielded power cable, characterized in that, It includes a conductor layer, a fastening layer, an insulating layer, a shielding layer, and a sheath layer arranged coaxially from the inside out; After being heated and shrinking, the fastening layer forms a tight compression-bonded structure with the outer surface of the conductor layer; After being heated and shrinking, the shielding layer forms a tight electromagnetic shielding contact with the outer surface of the insulating layer.

2. The high-flexibility tensile-strength shielded power cable according to claim 1, characterized in that, The conductor layer is made of multiple strands of soft copper wires twisted together, and the conductor cross-sectional area is 4-25 mm².

3. The high-flexibility tensile-strength shielded power cable according to claim 1, characterized in that, The fastening layer is a heat-shrinkable braided sleeve with a braiding density of ≥80% and a wall thickness of 0.2-0.8 mm after heat shrinking.

4. The high-flexibility tensile-strength shielded power cable according to claim 1, characterized in that, The shielding layer is a heat-shrinkable tubing with electromagnetic shielding function. The shielding layer structure includes an outer heat-shrinkable plastic layer and an inner metal wire braided mesh layer.

5. The high-flexibility tensile-strength shielded power cable according to claim 4, characterized in that, The metal wire woven mesh layer is made of tin-plated copper wire or copper wire.

6. The highly flexible tensile-strength shielded power cable according to any one of claims 1-5, characterized in that, The original inner diameter D1 of the shielding layer before heat shrinking and the outer diameter D2 of the insulating layer satisfy the following condition: 1.1≤D1 / D2≤1.2; the inner diameter D1' of the shielding layer after heat shrinking and the outer diameter D2 of the insulating layer satisfy the following condition: 1.02≤D1' / D2≤1.

08.

7. The high-flexibility tensile-strength shielded power cable according to claim 1, characterized in that, The heat-shrinkable shielding layer has a wall thickness of 0.2mm-0.6mm.

8. The high-flexibility tensile-strength shielded power cable according to claim 1, characterized in that, The thickness of the sheath layer is 2-5mm.

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