Corrosion-resistant photovoltaic cable for high-altitude areas

Abstract

The utility model discloses a kind of corrosion-resistant photovoltaic cables for high-altitude area, including reinforcing core, conductor, semi-conductive shielding layer and insulating layer, the reinforcing core, conductor, semi-conductive shielding layer and insulating layer are coaxially arranged in order from inside to outside, the semi-conductive shielding layer is adhered and fixed with the insulating layer in molten state by extrusion process, the insulating layer outside is sequentially provided with double shielding layer, weather-resistant isolation layer, water-blocking buffer layer, anti-biting layer and sheath layer using coaxial composite structure, the utility model is provided with ultraviolet resistant coating outside sheath layer, can improve ultraviolet reflectivity, greatly reduce surface temperature rise, insulating layer and sheath layer use irradiation crosslinking process, temperature range is widened to-40~ DEG C to 125~ DEG C, can resist extreme temperature difference impact, additionally increase anti-biting layer, it uses physical+chemical dual anti-biting structure, greatly prolongs anti-biting invalidation time, guarantees the structural integrity of cable in biological active area.

Description

Technical Field

[0001] This utility model mainly relates to the field of photovoltaic cable technology, specifically a corrosion-resistant photovoltaic cable for use in high-altitude areas. Background Technology

[0002] Photovoltaic cables are special cables designed specifically for solar photovoltaic systems. They are mainly used to connect photovoltaic modules, inverters, combiner boxes and other equipment to transmit DC or AC power.

[0003] Because it needs to be exposed to complex outdoor environments for a long time, it has strict requirements for weather resistance, temperature resistance, insulation, and mechanical strength. Its performance directly affects the safety and service life of the photovoltaic system. Especially in high-altitude areas, the operating environment of photovoltaic systems is more severe than that in low-altitude areas. This makes higher and more targeted requirements for the "corrosion resistance" of photovoltaic cables. However, existing photovoltaic cables are prone to sheath aging and cracking and moisture intrusion under strong ultraviolet radiation, extreme temperature differences, and humid condensation. In addition, due to the presence of active wild animals in high-altitude areas, the single sheath layer is easily gnawed and damaged by rodents such as pikas and marmots, resulting in exposure of the internal structure and causing short circuits or failures. Utility Model Content

[0004] This utility model addresses the problem that existing technical solutions are too simplistic by providing a corrosion-resistant photovoltaic cable for high-altitude areas. This solution addresses the technical problems mentioned in the background section, such as the aging and cracking of the sheath, moisture intrusion, and easy damage to the single sheath layer by rodents in high-altitude environments, which can lead to failures.

[0005] The technical solution adopted by this utility model to solve the above-mentioned technical problems is as follows: A corrosion-resistant photovoltaic cable for high-altitude areas includes a reinforcing core, a conductor, a semi-conductive shielding layer, and an insulation layer. The reinforcing core, conductor, semi-conductive shielding layer, and insulation layer are coaxially arranged from the inside to the outside. The semi-conductive shielding layer is bonded and fixed to the insulation layer in a molten state by an extrusion process. The insulation layer is provided with a double shielding layer, a weather-resistant isolation layer, a water-blocking buffer layer, an anti-biting layer, and a sheath layer in a coaxial composite structure on the outside.

[0006] Furthermore, the conductor adopts a circular cross-section structure formed by twisting a single rare earth high-speed iron aluminum alloy in an S-direction, and is distributed in a ring on the outer wall of the reinforcing core. The conductor and the reinforcing core are tightly surrounded by a winding tape, which is spirally wound in both directions at a helical angle of ±15° to prevent the conductor from loosening.

[0007] Furthermore, the semiconductive shielding layer is an integrally formed tubular structure with conductive particles uniformly distributed inside, and the semiconductive shielding layer and the conductor are fused together through the gaps in the winding wires.

[0008] Furthermore, the double shielding layer is continuously disposed on the outside of the insulation layer along the axial direction of the cable. The double shielding layer includes an inner shielding structure and an outer shielding structure. The inner shielding structure is an aluminum-plastic composite tape wrapped around the outside of the insulation layer. The outer shielding structure is a mesh structure formed by tin-plated copper wires. The tin-plated copper wires are interlaced and wound around the outer periphery of the inner shielding structure to form a mesh wrapping structure. The insulation layer is a mesh cross-linked structure formed by high-energy ray irradiation treatment and is fixedly connected to the semi-conductive shielding layer by extrusion molding process.

[0009] Furthermore, the water-blocking buffer layer includes a polyester nonwoven fabric base film and a water-blocking coating distributed on the surface of the nonwoven fabric base film, which is in the shape of a strip. The water-blocking buffer layer is spirally wound around the outside of the weather-resistant isolation layer. The weather-resistant isolation layer is continuously arranged along the cable axis on the outside of the double shielding layer and completely covers the outer peripheral surface of the double shielding layer.

[0010] Furthermore, the anti-bite layer is a strip structure, and multiple strips completely cover the outer periphery of the water-blocking buffer layer by spiral winding. The interior of the strip has micro-protrusion structures evenly distributed.

[0011] Furthermore, the sheath layer is coated on the outside of the anti-bite layer by melt extrusion process, and the surface of the sheath layer is coated with an anti-ultraviolet coating, and the surface of the sheath layer has a granular structure.

[0012] Compared with the prior art, the beneficial effects of this utility model are as follows: 1. The outer sheath layer is coated with an anti-UV coating, which can improve the UV reflectivity and significantly reduce the surface temperature rise. The insulation layer and sheath layer adopt the radiation cross-linking process, which widens the temperature resistance range to -40℃ to 125℃, and can resist extreme temperature difference impact. It has strong adaptability to high-altitude extreme environments. Furthermore, the material of the water-blocking buffer layer can form a watertight barrier. Combined with the water vapor barrier capability of the double shielding layer, it can effectively block moisture penetration and solve the problem of shortened lifespan caused by insufficient environmental adaptability of existing cables.

[0013] 2. Compared with traditional cables, an additional anti-bite layer is added. It adopts a dual anti-bite structure of physical and chemical. First, the glass fiber reinforced polyamide tape forms a high-hardness physical barrier. Combined with the chemical repellency of permethrin microcapsules, the anti-bite failure time is greatly extended, ensuring the structural integrity of the cable in biologically active areas and making up for the shortcomings of existing cables in terms of single protection and insufficient performance in complex environments.

[0014] The present invention will be explained in detail below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0015] Figure 1 This is a partial structural schematic diagram of the main view of this utility model; Figure 2 This is a top view of the structure of this utility model; Figure 3 This is a partial cross-sectional structural diagram of the present invention.

[0016] Numbering on the map: 1. Reinforcing core; 2. Conductor; 3. Semi-conductive shielding layer; 4. Insulation layer; 5. Double shielding layer; 6. Weather-resistant isolation layer; 7. Water-blocking buffer layer; 8. Anti-bite layer; 9. Sheath layer. Detailed Implementation

[0017] To facilitate understanding of this utility model, a more comprehensive description of the utility model will be given below with reference to the accompanying drawings, which show several embodiments of the utility model. However, the utility model can be implemented in different forms and is not limited to the embodiments described in the text. On the contrary, these embodiments are provided to make the disclosure of the utility model more thorough and comprehensive.

[0018] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0019] Please refer to the appendix carefully. Figure 1-3 A corrosion-resistant photovoltaic cable for high-altitude areas includes a reinforcing core 1, a conductor 2, a semi-conductive shielding layer 3, and an insulation layer 4. The reinforcing core 1, conductor 2, semi-conductive shielding layer 3, and insulation layer 4 are arranged coaxially from the inside to the outside. The semi-conductive shielding layer 3 is bonded and fixed to the insulation layer 4 in a molten state through an extrusion process. The insulation layer 4 is provided with a double shielding layer 5, a weather-resistant isolation layer 6, a water-blocking buffer layer 7, an anti-biting layer 8, and a sheath layer 9 in a coaxial composite structure on the outside.

[0020] In this embodiment, as Figure 3 As shown, conductor 2 is a circular cross-section structure formed by twisting a single rare earth high-speed iron aluminum alloy in an S-direction, and is distributed in a ring on the outer wall of reinforcing core 1. The conductor 2 and reinforcing core 1 are tightly surrounded by a winding strip, which is spirally wound in both directions at a helical angle of ±15° to prevent conductor 2 from loosening.

[0021] Through the above structure, a single rare earth high-speed rail aluminum alloy strand is twisted in the S direction to form a circular cross section. Combined with the structure of the reinforcing core 1 distributed in a ring on the outer wall, it takes into account both conductivity and structural stability. In addition, the ±15° bidirectional spiral winding tape can effectively prevent the conductor 2 from loosening and enhance the overall tensile strength. The material of the conductor 2 is more corrosion resistant than traditional copper, making it suitable for high-altitude environments. The reinforcing core 1 and the winding tape work together to resist the tensile force during laying, ensuring the stability of the conductor 2.

[0022] In this embodiment, as Figure 3 As shown, the semi-conductive shielding layer 3 is an integrally formed tubular structure with conductive particles uniformly distributed inside. The semi-conductive shielding layer 3 and the conductor 2 are fused together through the gap of the winding wire.

[0023] Through the above structure, the integrally formed tubular structure ensures a uniform electric field distribution and eliminates the risk of partial discharge. The conductive particles distributed inside can form a stable three-dimensional conductive network, which improves the shielding effectiveness. The fusion connection between it and conductor 2 through the gap of the winding wire makes the interface tightly bonded without loosening, adapting to high-altitude temperature difference deformation and ensuring long-term stability.

[0024] In this embodiment, as Figure 1 , Figure 2 and Figure 3 As shown, the double shielding layer 5 is continuously disposed on the outside of the insulation layer 4 along the axial direction of the cable. The double shielding layer 5 includes an inner shielding structure and an outer shielding structure. The inner shielding structure is an aluminum-plastic composite tape wrapped around the outside of the insulation layer 4. The outer shielding structure is a mesh structure formed by tin-plated copper wires. The tin-plated copper wires are wrapped around the outer periphery of the inner shielding structure in an interlaced manner to form a mesh wrapping structure. The insulation layer 4 is a mesh cross-linked structure formed by high-energy ray irradiation treatment and is fixedly connected to the semi-conductive shielding layer 3 by extrusion molding process.

[0025] Through the above structure, the inner aluminum-plastic composite tape wrapping can block low-frequency electromagnetic interference and water vapor penetration, while the outer tin-plated copper wire interlaced can efficiently attenuate high-frequency interference. The two work together to improve the shielding performance, and the tin plating layer can also prevent the copper wire from oxidizing in the high-altitude condensation environment. It takes into account both wideband shielding and environmental adaptability, and solves the problem that traditional single-layer shielding is difficult to take into account both high and low frequency interference and weather resistance.

[0026] In this embodiment, as Figure 1 , Figure 2 and Figure 3 As shown, the water-blocking buffer layer 7 includes a polyester nonwoven fabric base film and a water-blocking coating distributed on the surface of the nonwoven fabric base film. The whole is in the shape of a strip. The water-blocking buffer layer 7 is spirally wound around the outside of the weather-resistant isolation layer 6. The weather-resistant isolation layer 6 is continuously arranged along the cable axis on the outside of the double shielding layer 5 and completely covers the outer periphery of the double shielding layer 5.

[0027] Through the above structure, in order to avoid the potential danger of water intrusion due to the special nature of the high-altitude environment, the existence of the water-blocking buffer layer 7 can make up for the limitations of the outer protection. Its composite structure can form a watertight barrier when water breaks through the tiny gaps of the anti-biting layer 8 and the sheath layer 9, blocking water from contacting the inner layer and ensuring the stability of the cable's electrical performance.

[0028] In this embodiment, as Figure 1 , Figure 2 and Figure 3 As shown, the anti-bite layer 8 is a strip structure. The multiple strips completely cover the outer periphery of the water-blocking buffer layer 7 by spiral winding. The interior of the strip has micro-protrusion structures evenly distributed.

[0029] Through the above structure, the internal microcapsules form a micro-protrusion structure. First, the multi-layer glass fiber reinforced polyamide ribbon structure forms a preliminary physical barrier through spiral winding. With its high hardness, it directly resists the biting of rodents such as plateau pikas and marmots. At the same time, the 0.5% permethrin microcapsules with a particle size of 15-50μm added to the ribbon further form a chemical repellency barrier. The two work together to extend the anti-biting failure time and effectively ensure the structural integrity of the cable in biologically active areas, which is something that traditional cables cannot achieve.

[0030] In this embodiment, as Figure 1 , Figure 2 and Figure 3 As shown, the sheath layer 9 is coated on the outside of the anti-bite layer 8 by melt extrusion process, and the surface of the sheath layer 9 is coated with an anti-ultraviolet coating, and the surface of the sheath layer 9 has a granular structure.

[0031] Through the above structure, the granular structure on the surface of the sheath layer 9 can increase the friction with the outside, reduce the sliding displacement of the cable caused by wind vibration and dragging during laying or use. At the same time, the gaps between the particles can disperse rainwater and dust adhesion, and together with the anti-ultraviolet coating, improve the hydrophobic and anti-fouling performance, further enhancing the durability of the sheath layer 9.

[0032] The specific operating procedure of this utility model is as follows: It should be noted that this manual focuses on the structure of a single high-altitude photovoltaic cable. The illustration only shows the structure of a single cable and does not involve the connection end of the photovoltaic equipment. In actual use, the cable can be electrically connected to the corresponding connection end according to the interface type of the photovoltaic module, such as MC4 connectors, terminal blocks, etc. The layers of this high-altitude photovoltaic cable work together through specific materials and structures to achieve resistance to extreme high-altitude environments and ensure functional stability. The following describes the functional performance of each layer from the perspective of specific scenarios and material characteristics.

[0033] Firstly, in the high-altitude photovoltaic power station installation scenario, the conductor 2 uses rare earth high-speed iron aluminum alloy, which is an existing technology. The core 1 of polyaramid fiber is embedded in the center, which can improve tensile strength and effectively resist deformation when subjected to tensile stress in mountainous areas. The optimized crystal structure of rare earth elements improves the resistance to salt spray corrosion, adapts to the high-altitude foggy and humid corrosive environment, and ensures the long-term stability of the core carrier of power transmission.

[0034] The winding wire used to fix conductor 2 and reinforcing core 1 is made of low-density polyethylene wire, which is tightly wound at a spiral angle of ±15°. Its melting point of 105-115° is lower than the extrusion temperature of the subsequent semi-conductive shielding layer 3 (160-180°). When the semi-conductive shielding layer 3 is melted and extruded, the surface of the winding wire softens, allowing the melt of the semi-conductive shielding layer 3 to penetrate to the surface of conductor 2 and form a tight fixation. At the same time, the material of the winding wire has no chemical conflict with conductor 2 and reinforcing core 1, which can avoid the risk of corrosion and ensure that conductor 2 and reinforcing core 1 do not loosen during long-term use.

[0035] The semiconductive shielding layer 3 is made of the same material as the wound wire, with low-density polyethylene as the base material, and 30% nano carbon black (particle size 20nm) and 0.5% ultraviolet absorber UV-531 added. This is a publicly available technology. It is fixed to the conductor 2 by a three-layer co-extrusion process. The synergistic effect of carbon black and UV absorber can resist the aging of strong ultraviolet rays at high altitudes, solve the problem of no shielding or easy cracking of shielding layer in ordinary cables, and ensure the long-term effectiveness of electric field uniformity.

[0036] Insulation layer 4 is made of irradiated cross-linked halogen-free, low-smoke, flame-retardant polyolefin. This material can form a network cross-linked structure after being treated with high-energy electron beams. It can achieve continuous molten coating through extrusion process. Therefore, the material does not crack under impact at extreme low temperatures, can withstand the severe cold of high-altitude winters, and has a flame retardant rating of UL94V-0. It can adapt to the temperature rise of photovoltaic equipment at a high temperature of 125℃, which is better than the upper limit of 90℃ for ordinary photovoltaic cables, providing a reliable insulation barrier for power transmission.

[0037] The inner shielding structure of the double shielding layer 5 is an aluminum-plastic composite tape, which is tightly bonded by its own tension to form a closed wrap. The outer shielding is tin-plated copper wire, which is wrapped around the outer periphery of the inner aluminum-plastic composite tape in an interlaced braiding manner to form a stable mesh structure. There is no obvious gap between the inner aluminum-plastic composite tape and the outer shielding, and it can change synchronously with the bending and deformation of the cable. In high-altitude photovoltaic power station scenarios, the inner aluminum-plastic composite tape blocks low-frequency electromagnetic interference ≤1MHz and water vapor penetration by relying on the tightness of the longitudinal overlap. The outer tin-plated copper wire braided mesh can attenuate high-frequency interference of 1-300MHz. The double shielding effectiveness is relatively improved compared with ordinary cables. In high-altitude condensation environments, the two work together to provide reliable electromagnetic shielding for the internal structure of the cable.

[0038] The weather-resistant barrier layer 6 of cross-linked polyethylene is placed on the outside of the double shielding layer 5 through an extrusion process. With its weather-resistant properties, it effectively isolates the external environment from the inner structure, reduces the direct impact of high altitude and strong ultraviolet radiation and day-night temperature difference on the double shielding layer 5 and the insulation layer 4, and provides an additional environmental protection barrier for the inner structure.

[0039] The composite structure of the water-blocking buffer layer 7, through spiral winding with an overlap ratio, allows the highly absorbent resin component in the water-blocking coating to quickly absorb water and expand in a short time when encountering scenarios such as snow melting, rainy season water accumulation, or humid condensation in the actual use of high-altitude photovoltaic power stations. With the help of the spiral winding overlap structure, a continuous watertight barrier is formed, effectively blocking water from penetrating inward. The polyester non-woven fabric base film (gram weight 20g / m²) has a certain anti-breakage strength and can resist the impact of external sand and gravel during cable laying or operation, buffering the compressive stress on the internal structure, combined with the tight fit characteristics of spiral winding.

[0040] The biomimetic anti-bite layer 8 is made of multi-layered strip-structured glass fiber reinforced polyamide spirally wound, which can resist the biting of rodents such as plateau pikas and marmots. In addition, 0.5% permethrin microcapsules with a particle size of 15-50μm can be added during the winding process of the strip structure, forming a chemical repellency barrier on the basis of the physical barrier, which extends the anti-bite failure time compared with ordinary cables and ensures the integrity of the cable in biologically active areas as much as possible.

[0041] The sheath layer 9 and the biomimetic anti-bite layer 8 are fixed by close bonding. The gaps and textures formed by the spiral winding of the anti-bite layer 8 allow the sheath layer 9 to be fully impregnated and filled when it is melted and extruded. It can change synchronously with the bending and deformation of the cable without relative loosening. It is made of halogen-free low-smoke flame-retardant polyolefin, which has good strength and flame-retardant properties, and is suitable for high-altitude environments with strong ultraviolet radiation and large temperature differences between day and night, thus delaying aging. At the same time, the surface is coated with an anti-ultraviolet coating, which effectively reduces the surface temperature of the sheath layer 9 and reduces the impact of high temperature on the sheath layer 9 and its internal structure.

[0042] The present invention has been described above by way of example in conjunction with the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvement made by adopting the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other occasions without modification, shall be within the protection scope of the present invention.

Claims

1. A corrosion-resistant photovoltaic cable for high-altitude areas, comprising a reinforcing core (1), a conductor (2), a semi-conductive shielding layer (3), and an insulation layer (4), characterized in that: The reinforcing core (1), conductor (2), semi-conductive shielding layer (3) and insulating layer (4) are arranged coaxially from the inside to the outside. The semi-conductive shielding layer (3) is bonded and fixed to the insulating layer (4) in a molten state by an extrusion process. The insulating layer (4) is provided with a double shielding layer (5), a weather-resistant isolation layer (6), a water-blocking buffer layer (7), an anti-biting layer (8) and a sheath layer (9) in a coaxial composite structure on the outside.

2. The corrosion-resistant photovoltaic cable for high-altitude areas according to claim 1, characterized in that: The conductor (2) adopts a circular cross-section structure formed by twisting a single rare earth high-speed iron aluminum alloy in the S direction, and is distributed in a ring on the outer wall of the reinforcing core (1). The conductor (2) and the reinforcing core (1) are tightly surrounded by a winding strip. The winding strip is wound in a bidirectional spiral with a spiral angle of ±15° to prevent the conductor (2) from loosening.

3. The corrosion-resistant photovoltaic cable for high-altitude areas according to claim 1, characterized in that: The semiconductive shielding layer (3) is an integrally formed tubular structure with conductive particles evenly distributed inside. The semiconductive shielding layer (3) and the conductor (2) are fused together through the gap of the winding wire.

4. The corrosion-resistant photovoltaic cable for high-altitude areas according to claim 1, characterized in that: The double shielding layer (5) is continuously disposed on the outside of the insulation layer (4) along the axial direction of the cable. The double shielding layer (5) includes an inner shielding structure and an outer shielding structure. The inner shielding structure is an aluminum-plastic composite tape wrapped around the outside of the insulation layer (4). The outer shielding structure is a mesh structure formed by tin-plated copper wires. The tin-plated copper wires are wrapped around the outer periphery of the inner shielding structure in an interlaced manner to form a mesh wrapping structure. The insulation layer (4) is a mesh cross-linked structure formed by high-energy ray irradiation treatment and is fixedly connected to the semi-conductive shielding layer (3) by extrusion molding process.

5. The corrosion-resistant photovoltaic cable for high-altitude areas according to claim 1, characterized in that: The water-blocking buffer layer (7) includes a polyester nonwoven fabric base film and a water-blocking coating distributed on the surface of the nonwoven fabric base film. The whole is strip-shaped. The water-blocking buffer layer (7) is spirally wound around the outside of the weather-resistant isolation layer (6). The weather-resistant isolation layer (6) is continuously arranged along the cable axis on the outside of the double shielding layer (5) and completely covers the outer periphery of the double shielding layer (5).

6. The corrosion-resistant photovoltaic cable for high-altitude areas according to claim 1, characterized in that: The anti-bite layer (8) is a strip structure. Multiple strips completely cover the outer periphery of the water-blocking buffer layer (7) by spiral winding. The strip has micro-protrusion structures evenly distributed inside.

7. The corrosion-resistant photovoltaic cable for high-altitude areas according to claim 1, characterized in that: The sheath layer (9) is coated on the outside of the anti-bite layer (8) by melt extrusion process, and the surface of the sheath layer (9) is coated with an anti-ultraviolet coating, and the surface of the sheath layer (9) has a granular structure.

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