Multilayer insulation high temperature resistant teflon wire

Abstract

This invention provides a multi-layer insulated high-temperature resistant Teflon wire, comprising a wire body, which includes an inner core, a first insulating block, a second insulating block, and an outer sheath arranged concentrically from the inside out. The inner core has a cylindrical structure with conductive wires inside. The first insulating block is arranged on the outside of the inner core, and its cross-section is not circular. The second insulating block is composed of multiple hexagonal cavities extending along the axial direction of the wire body and arranged around the first insulating block, with phase change material filling the cavities. This invention introduces a second insulating block filled with phase change material. When the wire temperature rises due to high current operation, the phase change material in the hexagonal cavities can absorb a large amount of latent heat at its phase change temperature, thereby effectively suppressing the rapid rise in wire temperature and acting as a "thermal buffer."

Description

Technical Field

[0001] This utility model relates to the field of electrical wires, specifically a multi-layer insulated high-temperature resistant Teflon wire. Background Technology

[0002] As crucial carriers of power and signal transmission, wires and cables play a vital role in modern industry, transportation, aerospace, and civilian sectors. With the development of electronic devices towards higher power, higher integration, and miniaturization, the heat generated by wires and cables during operation is also increasing. How to effectively manage the heat generated by wires and cables and prevent them from overheating has become a pressing technical challenge.

[0003] Currently, traditional wires and cables typically use a single insulation layer structure, such as polyvinyl chloride (PVC), polyethylene (PE), or Teflon (PTFE). These materials mainly rely on their insulation and thermal conductivity to resist heat. However, under extreme conditions such as high current, high ambient temperature, or continuous overload operation, the heat dissipation capacity and heat resistance of a single insulation layer are often insufficient. Heat accumulation can lead to accelerated aging and performance degradation of the insulation material, and even cause safety accidents such as short circuits, melting, or fires. Utility Model Content

[0004] The main purpose of this utility model is to overcome the shortcomings of the existing technology and provide a multi-layer insulated high-temperature resistant Teflon wire, which aims to solve the problems of heat accumulation, insulation aging and safety hazards caused by insufficient heat dissipation capacity of traditional wires.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] A multi-layer insulated high-temperature resistant Teflon wire, comprising a wire body, characterized in that: the wire body comprises an inner core, a first insulating block, a second insulating block and an outer sheath arranged concentrically from the inside out;

[0007] The inner core has a cylindrical structure and conductive wires are arranged inside it;

[0008] A first insulating block is provided on the outer side of the inner core, and the cross-section of the first insulating block is annular.

[0009] The second insulating block is composed of a plurality of hexagonal prism cavities that extend along the axial direction of the main body of the wire and are arranged around the first insulating block, and the cavities are filled with phase change blocks.

[0010] As a further optimization of this utility model, both the first insulating block and the second insulating block are discontinuous structures that are spaced apart along the axial direction of the wire.

[0011] As a further optimization of this utility model, the spacing between adjacent first insulating blocks is between 10 and 50 mm; the spacing between adjacent second insulating blocks is between 20 and 60 mm.

[0012] As a further optimization of this utility model, the side length of the hexagonal cavity is between 0.5mm and 2mm; the wall thickness of the cavity is between 0.1mm and 0.5mm.

[0013] As a further optimization of this utility model, the thickness of the outer skin is between 0.5 mm and 2 mm.

[0014] Compared with the prior art, the present invention has the following significant advantages:

[0015] 1. Excellent Temperature Control Performance: This invention uniquely introduces a second insulating block filled with phase change material. When the wire's temperature rises due to high current operation, the phase change material within the hexagonal cavity absorbs a large amount of latent heat at its phase change temperature, effectively suppressing the rapid rise in wire temperature and acting as a "thermal buffer." When the load decreases and the temperature drops, the phase change material releases the stored heat, achieving dynamic and intelligent temperature regulation of the wire, greatly improving the wire's thermal stability and operational safety. Furthermore, when the wire is in a high-temperature external environment (such as near an engine, furnace, or in a confined space), this phase change layer can also absorb heat from the outside, acting as a thermal barrier to slow the transfer of external high temperatures to the internal conductor, protecting the core and the first insulating block's performance stability and preventing accelerated aging due to environmental overheating.

[0016] 2. High structural strength and lightweight: The second insulation block adopts a honeycomb hexagonal array structure. This structure provides excellent mechanical support and compressive strength while achieving lightweight structure, which meets the requirements of modern equipment for lightweight cables.

[0017] 3. Multiple Insulation Protection: The main body of the wire includes a first and a second insulating block, providing double insulation protection, which significantly improves the electrical insulation performance and voltage withstand rating of the wire. Both the inner and outer layers are made of high-temperature resistant Teflon material, ensuring long-term reliable operation of the wire in high-temperature environments. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a three-dimensional structural diagram of an embodiment of the present utility model.

[0020] Explanation of reference numerals in the attached figures:

[0021] 1. Main body of the power cable;

[0022] 2. Inner core;

[0023] 3. First insulating block;

[0024] 4. Second insulating block; 41. Cavity; 42. Phase change block;

[0025] 5. Outer skin. Detailed Implementation

[0026] The accompanying drawings are for illustrative purposes only and should not be construed as limiting the scope of this patent. To better illustrate this embodiment, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product.

[0027] It will be understood by those skilled in the art that certain well-known structures and their descriptions may be omitted in the accompanying drawings. The technical solution of this utility model will be further described below with reference to the accompanying drawings and embodiments.

[0028] Example 1

[0029] like Figure 1 As shown in the figure, this embodiment discloses a multi-layered insulated high-temperature resistant Teflon wire. The main body 1 of the wire has a multi-layered concentric structure, which includes, from the inside to the outside: an inner core 2, a first insulating block 3, a second insulating block 4, and an outer sheath 5.

[0030] The inner core 2, located at the very center, is a cylindrical structure. Conductive wires, such as those made of multiple strands of copper or tin-plated copper wire, are installed inside to transmit current or signals. A first insulating block 3 tightly covers the outer side of the inner core 2. Its cross-section is annular, and it is made of Teflon (PTFE), which has excellent insulation and high-temperature resistance. This first insulating block 3 provides basic electrical insulation, isolating the conductive inner core 2 from the external structure. In a preferred embodiment, the first insulating block 3 is not continuously arranged along the entire length of the wire body 1, but rather is a segmented "insulating block." The axial spacing between adjacent insulating blocks can be between 10mm and 50mm. This design can improve the flexibility of the cable and save materials while ensuring insulation performance.

[0031] The second insulating block 4 surrounds the outer periphery of the first insulating block 3. The main structure of this insulating block consists of an array of multiple hexagonal cylindrical cavities 41 extending axially along the main wire body 1, forming a honeycomb-like structure, as shown in the attached diagram of a ring of hexagons arranged around the central circle. The walls of these hexagonal cavities 41 are also made of Teflon material, with a preferred side length between 0.5 mm and 2 mm and a preferred wall thickness between 0.1 mm and 0.5 mm, to maximize the internal volume while ensuring structural strength.

[0032] The key is that each hexagonal cavity 41 is filled with a phase change block 42. A phase change material is a substance capable of changing its state within a specific temperature range (such as a solid-liquid phase change) and absorbing or releasing a large amount of latent heat in the process. When the main body of the wire 1 is energized and heats up, reaching the melting point of the phase change material, the material begins to melt, absorbing a large amount of heat while its own temperature remains essentially constant, effectively preventing the core temperature of the main body of the wire 1 from continuously soaring. When the load on the main body of the wire 1 decreases and the temperature drops, the phase change material solidifies, releasing the previously absorbed heat. In this way, the second insulating block 4 acts as a passive, intelligent temperature control system. Similar to the first insulating block 3, the second insulating block 4 can also adopt a segmented design, with the spacing between adjacent segments ranging from 20mm to 60mm. Furthermore, when the external ambient temperature of the main body of the wire 1 is too high, the phase change block 42 can also function to reduce the impact of the external environment on the main body of the wire 1.

[0033] The outer sheath 5 is the outermost protective structure of the wire body 1. It completely covers the second insulation block 4, forming a complete and smooth appearance of the wire body 1. The outer sheath 5 is usually also made of Teflon or other wear-resistant, corrosion-resistant, and high-temperature-resistant polymer materials, mainly serving to provide mechanical protection, waterproofing, moisture protection, and resistance to external environmental corrosion. Its thickness is preferably between 0.5mm and 2mm to provide sufficient protection without sacrificing the flexibility of the wire body 1.

[0034] Summary of working principle:

[0035] On the one hand, regarding internal heat generation, when the current flows through the inner core 2 and generates Joule heat, the heat is conducted to the second insulating block 4. If the temperature of the main body 1 of the wire reaches the phase change point of the phase change material, the phase change block 42 in the cavity 41 will begin to melt and absorb a large amount of latent heat, effectively suppressing the continuous rise in conductor temperature.

[0036] On the other hand, the structure of this invention also performs excellently in resisting high-temperature external environments. When the wire body 1 is placed in an enclosed environment such as an engine compartment, near an industrial oven, or in a high-density wiring enclosure, external heat is conducted inward through the outer sheath 5. Before the heat reaches the inner core 2, it is first intercepted by the phase change material layer in the second insulation block 4. Similarly, the phase change material dissipates most of the incoming heat by absorbing latent heat, thereby forming an effective "thermal barrier" between the external heat source and the internal conductor. This significantly delays and reduces the temperature rise of the internal conductor, protecting its physical properties and the insulation integrity of the first insulation block, and avoiding performance degradation or safety accidents caused by environmental overheating.

[0037] In summary, the structure of the main body 1 of this wire transforms the traditional passively insulated cable into an intelligent functional cable capable of active bidirectional heat management, thereby greatly improving the current carrying capacity, environmental adaptability, safety and service life of the main body 1 under various extreme working conditions.

[0038] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating this utility model, and are not intended to limit the implementation of this utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. A multi-layer insulated high-temperature resistant Teflon wire, comprising a wire body, characterized in that: The main body of the wire includes an inner core, a first insulating block, a second insulating block, and an outer sheath arranged concentrically from the inside out; The inner core has a cylindrical structure and conductive wires are arranged inside it; A first insulating block is provided on the outer side of the inner core, and the cross-section of the first insulating block is in the shape of a missing circle. The second insulating block is composed of multiple hexagonal prism cavities that extend along the axial direction of the wire body and are arranged around the first insulating block, and the cavities are filled with phase change blocks; The first insulating block and the second insulating block are both spaced apart. The spacing between adjacent first insulating blocks is between 10 and 50 mm; The spacing between adjacent second insulating blocks is between 20 and 60 mm.

2. The multi-layer insulated high-temperature resistant Teflon wire according to claim 1, characterized in that: The side length of the cavity is between 0.5 mm and 2 mm; The wall thickness of the cavity is between 0.1 mm and 0.5 mm.

3. The multi-layer insulated high-temperature resistant Teflon wire according to claim 1, characterized in that: The thickness of the outer skin is between 0.5 mm and 2 mm.

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