High-flexibility bend-resistant special cable

Abstract

This utility model relates to the field of cable technology, and in particular to a highly flexible and bend-resistant special cable, comprising a cable body, which includes, from the inside out, a conductor, an insulation layer, a shielding layer, a filler layer, and a composite sheath layer; the conductor is made of multiple strands of tinned copper wire twisted together, with the diameter of the tinned copper wire being 0.05-0.15mm; the insulation layer is made of modified silicone rubber material, with protrusions on the inner side of the insulation layer that fit into grooves on the outer surface of the conductor; the shielding layer includes an aluminum-plastic composite tape wrapping layer and a tinned copper wire braided layer, with a braiding density of ≥90%; the filler layer is made of highly elastic polyurethane foam material with a foaming density of 80-120kg / m³; the composite sheath layer is a multi-layer co-extruded structure, including, from the inside out, a nylon inner sheath layer, a glass fiber middle sheath layer, and a TPU outer sheath layer; this utility model, through structural design and optimization, exhibits excellent performance in terms of flexibility, bend resistance, anti-interference, wear resistance, and service life, meeting application requirements.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, and in particular to a highly flexible and bend-resistant special cable. Background Technology

[0002] In modern industry and electronic equipment, many scenarios, such as robot joint movements, precision instrument wiring, and mobile device connections, place extremely high demands on the flexibility and bending resistance of cables. However, traditional cables typically suffer from the following shortcomings: unreasonable conductor structure design, often employing single strands or simple stranded structures, making them prone to breakage or poor contact under frequent bending; insufficient bonding strength between the insulation layer and the conductor, potentially leading to displacement or wear during bending and a decline in insulation performance; a simple shielding layer structure with poor shielding effect, making it difficult to effectively resist external electromagnetic interference; and single-layer sheath materials with poor toughness and abrasion resistance, easily cracking and breaking after long-term bending, thus affecting the overall service life and reliability of the cable. Therefore, there is an urgent need for a special cable that can combine high flexibility, bending resistance, interference resistance, and long lifespan to meet the needs of complex application scenarios. Utility Model Content

[0003] To address some of the problems existing in the prior art, this utility model provides a highly flexible and bend-resistant special cable. Through various structural designs and optimizations, this cable exhibits excellent performance in terms of flexibility, bend resistance, anti-interference, wear resistance, and service life, meeting the application requirements of high dynamic bending scenarios.

[0004] To achieve the above objectives, this utility model provides a highly flexible and bend-resistant special cable, comprising a cable body, which includes a conductor, an insulation layer, a shielding layer, a filling layer, and a composite sheath layer arranged sequentially from the inside out; the conductor is made of multiple strands of tinned copper wire twisted together, and the diameter of the tinned copper wire is 0.05-0.15mm; the insulation layer is made of modified silicone rubber material, and the inner side of the insulation layer has protrusions that fit into grooves on the outer surface of the conductor; the shielding layer includes an aluminum-plastic composite tape wrapping layer and a tinned copper wire braided layer, and the braiding density of the tinned copper wire braided layer is ≥90%; the filling layer is a highly elastic polyurethane foam material with a foaming density of 80-120kg / m³; the composite sheath layer is a multi-layer co-extruded structure, including a nylon inner sheath layer, a glass fiber middle sheath layer, and a TPU outer sheath layer arranged sequentially from the inside out.

[0005] In operation, the conductor, acting as an energy transmission carrier, directs current from one end to the other. Its multi-strand tinned copper wire stranded structure ensures flexibility and disperses bending stress. The insulation layer, made of modified silicone rubber, tightly wraps the conductor, with inner protrusions interlocking with outer grooves to eliminate bending gaps, prevent current leakage, and improve wear resistance. The aluminum-plastic composite tape wrapping layer in the shielding layer wraps around the insulation layer with a 20-30% overlap, blocking external electromagnetic interference and internal electromagnetic field leakage. The tinned copper wire braided layer, with a density of ≥90% and a braiding angle of 45-55°, further enhances the shielding effectiveness. Maintaining flexibility; the filler layer uses highly elastic polyurethane foam to fill internal gaps, buffering mechanical impacts and maintaining structural stability; the nylon inner sheath layer in the composite sheath layer provides basic wear resistance and tear resistance, the glass fiber middle sheath layer enhances high temperature resistance and mechanical strength, the TPU outer sheath layer improves tensile strength through axial carbon fiber reinforcement strips, and the anti-slip texture on the outer surface reduces installation friction. Its multi-layer structure works together to resist bending, stretching and environmental erosion; silica spheres are evenly distributed around the conductor to optimize the electric field distribution and assist in heat dissipation, ensuring that the cable can still transmit current stably under repeated bending and high temperature environments.

[0006] The beneficial effects of this utility model are as follows: The conductor in this utility model is made of multiple strands of tin-plated copper wire twisted together, with a twist pitch of 8 to 12 times the outer diameter of the conductor and adjacent strands twisted in opposite directions. This design ensures excellent conductivity and imparts outstanding flexibility to the conductor, reducing stress concentration during bending. The insulation layer uses modified silicone rubber material, with its inner protrusions interlocking with the outer grooves of the conductor. Combined with evenly distributed silica spheres, this not only enhances insulation performance but also further improves bending resistance through structural interlocking and elastic support. The shielding layer consists of an aluminum-plastic composite tape wrapping layer and a tin-plated copper wire braided layer, providing a double shielding structure. It effectively blocks external electromagnetic interference, ensuring the stability of signal transmission; the filler layer can play a good buffering role when the cable is bent, dispersing stress and preventing damage to the internal structure; the composite sheath layer adopts a multi-layer co-extrusion structure of nylon inner sheath, glass fiber middle sheath and TPU outer sheath, combined with carbon fiber reinforcing strips distributed along the axis, so that the sheath layer has the wear resistance of nylon, the tensile strength of glass fiber and the high elasticity of TPU, which significantly improves the mechanical strength and bending life of the cable. At the same time, the anti-slip texture and model markings on the outer surface of the TPU outer sheath layer not only enhance the convenience of operation during use, but also facilitate quick identification of the cable model.

[0007] As a further improvement of this utility model, in order to reduce stress concentration during bending and enhance the flexibility and structural stability of the conductor, the stranding pitch of the conductor is 8 to 12 times the outer diameter of the conductor, and the stranding directions of adjacent stranded layers are opposite.

[0008] As a further improvement of this utility model, in order to enhance the electromagnetic shielding effect and improve the signal transmission stability, the wrapping overlap rate of the aluminum-plastic composite tape wrapping layer is 20-30%, and the weaving angle of the tin-plated copper wire braiding layer is 45-55°.

[0009] As a further improvement of this utility model, in order to reduce the deformation of the insulation layer during bending and improve the bending resistance, a plurality of silica spheres are provided in the insulation layer, and the silica spheres are evenly distributed around the center of the conductor.

[0010] As a further improvement of this utility model, in order to enhance the wear resistance, tensile strength and elasticity of the sheath through the synergistic effect of the multi-layer structure, the thickness ratio of the nylon inner sheath layer, the glass fiber middle sheath layer and the TPU outer sheath layer is 2:3:5, and the thickness of the nylon inner sheath layer is 0.1 to 0.25 mm.

[0011] As a further improvement of this utility model, in order to enhance mechanical strength and optimize operational convenience and recognizability, carbon fiber reinforcing strips are uniformly embedded in the TPU outer sheath layer, and the carbon fiber reinforcing strips are distributed along the cable axis; the outer surface of the TPU outer sheath layer is provided with anti-slip texture and is sprayed with corresponding model markings. Attached Figure Description

[0012] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings: Figure 1 This is a schematic cross-sectional view of the overall structure of this utility model.

[0013] The components include: 1. Conductor; 2. Insulation layer; 3. Aluminum-plastic composite tape wrapping layer; 4. Tinned copper wire braided layer; 5. Filler layer; 6. Nylon inner sheath layer; 7. Glass fiber middle sheath layer; 8. TPU outer sheath layer; 9. Silica spheres; and 10. Carbon fiber reinforcing strips. Detailed Implementation

[0014] like Figure 1The cable shown is a highly flexible and bend-resistant special cable, comprising a cable body, which includes, from the inside out, a conductor 1, an insulation layer 2, a shielding layer, a filling layer 5, and a composite sheath layer; the conductor 1 is made of multiple strands of tin-plated copper wire twisted together, and the diameter of the tin-plated copper wire is 0.05-0.15mm; the insulation layer 2 is made of modified silicone rubber material, and the inner side of the insulation layer 2 has protrusions that fit into grooves on the outer surface of the conductor 1; the shielding layer includes an aluminum-plastic composite tape wrapping layer 3 and a tin-plated copper wire braided layer 4, and the braiding density of the tin-plated copper wire braided layer 4 is ≥90%; the filling layer 5 is a highly elastic polyurethane foam material with a foaming density of 80-120kg / m³; the composite sheath layer is a multi-layer co-extruded structure, including, from the inside out, a nylon inner sheath layer 6, a glass fiber middle sheath layer 7, and a T-type sheath layer. The cable consists of a PU outer sheath layer 8; the stranding pitch of the conductor 1 is 8 to 12 times the outer diameter of the conductor 1, and the stranding directions of adjacent stranded layers are opposite; the wrapping overlap rate of the aluminum-plastic composite tape wrapping layer 3 is 20 to 30%, and the braiding angle of the tinned copper wire braiding layer 4 is 45 to 55°; multiple silica spheres 9 are uniformly distributed circumferentially around the center of the conductor 1 within the insulation layer 2; the thickness ratio of the nylon inner sheath layer 6, the glass fiber middle sheath layer 7, and the TPU outer sheath layer 8 is 2:3:5, and the thickness of the nylon inner sheath layer 6 is 0.1 to 0.25 mm; carbon fiber reinforcing strips 10 are uniformly embedded within the TPU outer sheath layer 8, and the carbon fiber reinforcing strips 10 are distributed along the cable axis; the outer surface of the TPU outer sheath layer 8 is provided with anti-slip texture and is sprayed with corresponding model markings.

[0015] In operation, conductor 1, acting as an electrical energy transmission carrier, guides the current from one end to the other. Its multi-strand tinned copper wire stranded structure ensures flexibility and disperses bending stress. Insulation layer 2, made of modified silicone rubber, tightly wraps conductor 1. The inner protrusions and outer grooves of the conductor eliminate bending gaps, preventing current leakage and improving wear resistance. In the shielding layer, aluminum-plastic composite tape wrapping layer 3 wraps around insulation layer 2 with a 20-30% overlap, blocking external electromagnetic interference and internal electromagnetic field leakage. Tinned copper wire braided layer 4, with a density of ≥90% and a braiding angle of 45-55°, further enhances shielding effectiveness while ensuring... It maintains flexibility; the filler layer 5 uses high-elasticity polyurethane foam to fill the internal gaps, buffering mechanical impact and maintaining structural stability; the nylon inner sheath layer 6 in the composite sheath layer provides basic wear resistance and tear resistance, the glass fiber middle sheath layer 7 enhances high temperature resistance and mechanical strength, the TPU outer sheath layer 8 improves tensile strength through axial carbon fiber reinforcement strips 10, and the anti-slip texture on the outer surface reduces installation friction. Its multi-layer structure works together to resist bending, stretching and environmental erosion; silica spheres 9 are evenly distributed around the conductor 1 to optimize the electric field distribution and assist in heat dissipation, ensuring that the cable can still transmit current stably under repeated bending and high temperature environments.

[0016] The above description is merely a preferred embodiment of this utility model. The protection scope of this utility model is not limited to the above embodiments. All technical solutions falling within the scope of this utility model's concept are protected. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of this utility model should also be considered within the protection scope of this utility model.

Claims

1. A highly flexible and bend-resistant special cable, comprising a cable body, characterized in that: The cable body includes a conductor (1), an insulation layer (2), a shielding layer, a filling layer (5), and a composite sheath layer arranged sequentially from the inside to the outside; the conductor (1) is made of multiple strands of tin-plated copper wires twisted together, and the diameter of the tin-plated copper wires is 0.05 to 0.15 mm; the insulation layer (2) is made of modified silicone rubber material, and the inner side of the insulation layer (2) is provided with a protrusion that fits into the groove on the outer surface of the conductor (1); the shielding layer includes an aluminum-plastic composite tape wrapping layer (3) and a tin-plated copper wire braided layer (4), and the braiding density of the tin-plated copper wire braided layer (4) is ≥90%; the filling layer (5) is a high-elasticity polyurethane foam material with a foaming density of 80 to 120 kg / m³; the composite sheath layer is a multi-layer co-extruded structure, including a nylon inner sheath layer (6), a glass fiber middle sheath layer (7), and a TPU outer sheath layer (8) arranged sequentially from the inside to the outside.

2. The high flexibility, bend-insensitive specialty cable of claim 1, wherein: The stranding pitch of the conductor (1) is 8 to 12 times the outer diameter of the conductor (1), and the stranding directions of adjacent stranded layers are opposite.

3. The high flexibility, bend-insensitive specialty cable of claim 1, wherein: The wrapping overlap rate of the aluminum-plastic composite tape wrapping layer (3) is 20-30%, and the weaving angle of the tin-plated copper wire braided layer (4) is 45-55°.

4. The high flexibility, bend- resistant specialty cable of claim 1, wherein: Multiple silica spheres (9) are disposed within the insulating layer (2), and the silica spheres (9) are evenly distributed around the center of the conductor (1).

5. The high flexibility, bend- resistant specialty cable of claim 1 wherein: The thickness ratio of the nylon inner sheath layer (6), the glass fiber middle sheath layer (7), and the TPU outer sheath layer (8) is 2:3:5, and the thickness of the nylon inner sheath layer (6) is 0.1 to 0.25 mm.

6. The high flexibility, bend- resistant specialty cable of claim 1 wherein: The TPU outer sheath layer (8) is uniformly embedded with carbon fiber reinforcing strips (10), which are distributed along the cable axis; the outer surface of the TPU outer sheath layer (8) is provided with anti-slip texture and is sprayed with corresponding model markings.

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