High-conductivity copper-chromium-zirconium alloy strand structure

Abstract

The utility model discloses a high conductivity copper chromium zirconium alloy stranded wire structure, including metal core body, the metal core body outer wall is equipped with the elastic buffer layer, the elastic buffer layer outer wall is equipped with carbon fiber braided layer, the carbon fiber braided layer outer wall is equipped with the inner layer stranded wire, the inner layer stranded wire outer wall is equipped with the outer layer stranded wire, the inner layer stranded wire and outer layer stranded wire outer all are equipped with the conductive plating, the outer layer stranded wire outer wall is equipped with the rubber protective sheath. The utility model discloses through setting up the composite structure of metal core body, elastic buffer layer and carbon fiber braided layer, and metal core body provides basic rigidity, and elastic buffer layer can absorb external force impact, and carbon fiber braided layer enhances the torsional resistance, and the overall structural strength and the fatigue resistance of stranded wire are improved significantly through the synergistic effect of three, and the unstable problem of the conductive path caused by the damage of core structure is avoided effectively.

Description

Technical Field

[0001] This utility model relates to the field of metal stranded wire technology, and in particular to a high conductivity copper-chromium-zirconium alloy stranded wire structure. Background Technology

[0002] Metal stranded wire is a conductor made of multiple metal single wires (such as copper, aluminum, etc.) twisted together in a certain direction. The multi-strand structure improves flexibility, mechanical strength and anti-interference ability, and reduces the skin effect of high-frequency current.

[0003] Copper-chromium-zirconium alloys are widely used in conductive components due to their excellent combination of high strength and high conductivity. However, in practical use, existing copper-chromium-zirconium alloy stranded wires have a simple core support structure, relying on only a single metal core. When subjected to external impact or long-term bending, they are prone to deformation, which in turn destroys the stability of the overall conductive path. Furthermore, the twisting of the inner and outer strands lacks a reasonable design, and gaps easily appear between the layers, leading to increased contact resistance and seriously affecting conductivity, resulting in insufficient practicality. Therefore, it is necessary to redesign a high-conductivity copper-chromium-zirconium alloy stranded wire structure to address the above problems. Utility Model Content

[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing a highly conductive copper-chromium-zirconium alloy stranded wire structure.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A highly conductive copper-chromium-zirconium alloy stranded wire structure includes a metal core, an elastic buffer layer sleeved on the outer wall of the metal core, a carbon fiber braided layer sleeved on the outer wall of the elastic buffer layer, an inner stranded wire sleeved on the outer wall of the carbon fiber braided layer, an outer stranded wire sleeved on the outer wall of the inner stranded wire, a conductive plating layer on the outer surfaces of both the inner and outer stranded wires, and a rubber protective sleeve sleeved on the outer wall of the outer stranded wire.

[0006] Preferably, the metal core is tin-plated copper wire, the elastic buffer layer is hydrogenated nitrile rubber with a thickness of 0.2 mm to 0.3 mm, and the weaving density of the carbon fiber braided layer is 80% to 90%.

[0007] Preferably, the inner stranded wire is composed of six copper-chromium-zirconium alloy single wires twisted together, each copper-chromium-zirconium alloy single wire having a diameter of 0.15mm to 0.25mm, and the outer stranded wire is composed of eight copper-chromium-zirconium alloy single wires twisted together, each copper-chromium-zirconium alloy single wire having a diameter of 0.25mm to 0.4mm.

[0008] Preferably, the conductive coating is a composite coating, which consists of a nickel base layer and a silver surface layer from the inside out. The thickness of the nickel base layer is 0.003 mm to 0.005 mm, the thickness of the silver surface layer is 0.005 mm to 0.01 mm, and the thickness of the silver surface layer of the inner stranded wire 4 is 0.002 mm to 0.003 mm thicker than that of the outer stranded wire 5.

[0009] Preferably, the inner side of the rubber protective sleeve is provided with anti-slip texture, and the anti-slip texture is in contact with the surface of the outer stranded wire.

[0010] Preferably, the outer surface of the rubber protective sleeve is provided with axial raised stripes.

[0011] The beneficial effects of this utility model are: 1. By setting a composite structure of metal core, elastic buffer layer and carbon fiber braided layer, the metal core provides basic rigidity, the elastic buffer layer can absorb external impact, and the carbon fiber braided layer enhances torsional resistance. The three work together to significantly improve the overall structural strength and fatigue resistance of the stranded wire, effectively avoiding the problem of unstable conductive path caused by damage to the core structure.

[0012] 2. By setting reasonable stranding parameters for the inner and outer stranded wires and different composite coatings, the inner layer's fine-diameter single wire reduces the high-frequency skin effect, while the outer layer's thicker single wire improves structural strength. In the composite coating, the nickel base layer enhances adhesion, the silver surface layer improves conductivity, and the inner silver surface layer is thicker to strengthen the conductivity of the main conductive path, significantly reducing contact resistance and improving overall conductivity efficiency. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of a highly conductive copper-chromium-zirconium alloy stranded wire structure proposed in this utility model. Figure 2 for Figure 1 A schematic diagram of the vertical section structure; Figure 3 This is a side view of a high-conductivity copper-chromium-zirconium alloy stranded wire structure proposed in this utility model. Figure 4 for Figure 1 Enlarged schematic diagram of the structure at point A in the diagram; Figure 5 for Figure 3 Enlarged schematic diagram of the structure at point B in the diagram.

[0014] In the diagram: 1. Metal core, 2. Elastic buffer layer, 3. Carbon fiber braided layer, 4. Inner stranded wire, 5. Outer stranded wire, 6. Rubber protective sleeve. Detailed Implementation

[0015] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0016] Reference Figure 1-5 A highly conductive copper-chromium-zirconium alloy stranded wire structure includes a metal core 1, which is made of tin-plated copper wire, possessing excellent conductivity and oxidation resistance. As the core supporting component of the entire stranded wire structure, it provides the basic structural rigidity for the stranded wire. An elastic buffer layer 2 is fitted around the outer wall of the metal core 1. This elastic buffer layer 2 is made of hydrogenated nitrile rubber, which exhibits excellent oil resistance, temperature resistance, and elastic deformation capability. Its thickness is controlled between 0.2 mm and 0.3 mm, effectively absorbing external impact loads and preventing damage to the inner stranded wire 4 due to rigid impacts. A carbon fiber braided layer 3 is fitted around the outer wall of the elastic buffer layer 2. The braiding density of the carbon fiber braided layer 3 is 80%–90%. The high strength of carbon fiber significantly enhances the torsional resistance of the stranded wire, while simultaneously forming a flexible contact with the inner stranded wire 4, reducing stress concentration.

[0017] The outer wall of the carbon fiber braided layer 3 is fitted with an inner stranded wire 4, which is composed of six copper-chromium-zirconium alloy single wires twisted together. Each copper-chromium-zirconium alloy single wire has a diameter of 0.15mm to 0.25mm. The small diameter design helps to reduce the skin effect under high-frequency current and improve high-frequency conductivity. The outer wall of the inner stranded wire 4 is fitted with an outer stranded wire 5, which is composed of eight copper-chromium-zirconium alloy single wires twisted together. Each copper-chromium-zirconium alloy single wire has a diameter of 0.25mm to 0.4mm. The larger single wire diameter can improve the overall structural strength of the stranded wire and better cope with external mechanical stress. The inner stranded wire 4 and the outer stranded wire 5 are connected to the outer wall of the inner stranded wire 4. The outer stranded wires 5 are all coated with a conductive plating layer. The conductive plating layer is a composite plating layer, consisting of a nickel base layer and a silver surface layer from the inside out. The thickness of the nickel base layer is 0.003mm to 0.005mm, and its main function is to enhance the bonding force between the plating layer and the copper-chromium-zirconium alloy single wires and prevent the plating layer from peeling off. The thickness of the silver surface layer is 0.005mm to 0.01mm. The high conductivity of silver is used to reduce the contact resistance between the single wires. The silver surface layer of the inner stranded wire 4 is 0.002mm to 0.003mm thicker than that of the outer stranded wire 5 because the inner stranded wire 4 is the main conductive path and requires stronger conductivity.

[0018] The outer layer of stranded wire 5 is fitted with a rubber protective sleeve 6. The inner side of the rubber protective sleeve 6 is provided with anti-slip texture. The anti-slip texture is in close contact with the surface of the outer layer of stranded wire 5, which can prevent relative sliding between the rubber protective sleeve 6 and the outer layer of stranded wire 5 and ensure the stability of the structure. Flame retardants, such as aluminum hydroxide, are added to the rubber protective sleeve 6, which can improve the high temperature resistance and flame retardant performance of the protective sleeve. The outer surface of the rubber protective sleeve 6 is provided with axial raised stripes. These stripes can enhance the wear resistance of the protective sleeve and increase the friction between it and other components during installation, making it easier to install and fix.

[0019] When using this utility model, firstly, according to the needs of the specific application scenario, select components such as a metal core 1, an elastic buffer layer 2, a carbon fiber braided layer 3, an inner stranded wire 4, an outer stranded wire 5, and a rubber protective sleeve 6 with appropriate parameters. In the component pretreatment stage, the surface of the metal core 1 needs to be cleaned to remove oil and oxide layers, ensuring that the elastic buffer layer 2 can fit tightly. The raw material of the elastic buffer layer 2 is heated to a molten state and uniformly coated on the outer wall of the metal core 1 using an extrusion molding process. After cooling and solidification, a buffer layer of uniform thickness is formed. Next, the carbon fiber braided layer 3 is processed. The carbon fiber filaments are wound on the outer wall of the elastic buffer layer 2 on a special braiding machine at a braiding density of 80% to 90%. During the braiding process, a constant tension is maintained to avoid slack or over-tightness. For the inner stranded wire 4 and the outer stranded wire 5, the copper-chromium-zirconium alloy single wire is first pretreated by electrolytic cleaning to remove impurities. Then, an electroplating process is used to form a nickel base layer and a silver surface layer in sequence to ensure that the plating layer is uniform and free of pinholes. Subsequently, six inner stranded wires are twisted in a right-hand direction on a stranding machine to form the inner stranded wire 4, and eight outer stranded wires are twisted in a left-hand direction to form the outer stranded wire 5. During the stranding process, the stranding pitch is strictly controlled to ensure that the interlayer is tightly bonded. Finally, the rubber protective sleeve 6 is installed. The raw material of the inner layer rubber protective sleeve 6 with anti-slip texture is first heated and softened, and then wrapped on the outer wall of the outer stranded wire 5 through an extruder. After cooling, the anti-slip texture is fully engaged with the surface of the outer stranded wire 5 to complete the assembly of the overall structure. In actual installation and application, according to the installation requirements of the usage scenario, the axial raised stripes on the outer surface of the rubber protective sleeve 6 increase friction, making it easier for operators to hold and position. A certain length of the rubber protective sleeve 6 at both ends of the stranded wire is peeled off to expose the inner stranded wire 4 and the outer stranded wire 5. It is then connected to the terminal block using a special crimping tool to ensure tight contact and reduce connection resistance. After installation, the conductivity and insulation of the stranded wire are tested to ensure stable operation in the working environment. During routine maintenance, the rubber protective sleeve 6 is checked regularly for signs of wear and aging. If damage is found, it is replaced in time. At the same time, the connection parts of the stranded wire are checked for looseness to ensure the safety and reliability of the overall structure.

[0020] 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 highly conductive copper-chromium-zirconium alloy stranded wire structure, comprising a metal core (1), characterized in that, The outer wall of the metal core (1) is fitted with an elastic buffer layer (2), the outer wall of the elastic buffer layer (2) is fitted with a carbon fiber braided layer (3), the outer wall of the carbon fiber braided layer (3) is fitted with an inner stranded wire (4), the outer wall of the inner stranded wire (4) is fitted with an outer stranded wire (5), both the inner stranded wire (4) and the outer stranded wire (5) are fitted with a conductive plating layer, and the outer wall of the outer stranded wire (5) is fitted with a rubber protective sleeve (6).

2. The high conductivity copper-chromium-zirconium alloy stranded wire structure according to claim 1, characterized in that, The metal core (1) is tin-plated copper wire, the elastic buffer layer (2) is hydrogenated nitrile rubber with a thickness of 0.2mm to 0.3mm, and the weaving density of the carbon fiber braided layer (3) is 80% to 90%.

3. The high conductivity copper-chromium-zirconium alloy stranded wire structure according to claim 1, characterized in that, The inner stranded wire (4) is made of six copper-chromium-zirconium alloy single wires twisted together, each copper-chromium-zirconium alloy single wire having a diameter of 0.15mm to 0.25mm. The outer stranded wire (5) is made of eight copper-chromium-zirconium alloy single wires twisted together, each copper-chromium-zirconium alloy single wire having a diameter of 0.25mm to 0.4mm.

4. The high conductivity copper-chromium-zirconium alloy stranded wire structure according to claim 3, characterized in that, The conductive coating is a composite coating, which consists of a nickel base layer and a silver surface layer from the inside out. The thickness of the nickel base layer is 0.003mm to 0.005mm, and the thickness of the silver surface layer is 0.005mm to 0.01mm. The silver surface layer of the inner stranded wire (4) is 0.002mm to 0.003mm thicker than that of the outer stranded wire (5).

5. The highly conductive copper-chromium-zirconium alloy stranded wire structure according to claim 4, characterized in that, The inner side of the rubber protective sleeve (6) is provided with anti-slip texture, which is in contact with the surface of the outer stranded wire (5).

6. The highly conductive copper-chromium-zirconium alloy stranded wire structure according to claim 5, characterized in that, The outer surface of the rubber protective sleeve (6) is provided with axial raised stripes.

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