Flexible high temperature resistant cable

Abstract

The utility model discloses a kind of flexible high-temperature-resistant cables, comprising: conductor, the conductor is made of nickel-plated copper alloy wire and is twisted into two layers, the twisting pitch of inner layer conductor is less than the twisting pitch of outer layer conductor, and the twisting direction of inner layer conductor and outer layer conductor is opposite;Insulating layer, the insulating layer is set to the conductor outside, the insulating layer includes inner layer around and pack high-temperature-resistant mica tape layer and outer layer extrusion and pack silicone rubber layer;Copper wire braiding shielding layer, the copper wire braiding shielding layer is set to the insulating layer outside, copper wire in the copper wire braiding shielding layer is tinned treatment;Filling layer, the filling layer is filled in the conductor twisting gap place;Outer sheath, the outer sheath is set to the copper wire braiding shielding layer outside, the outer sheath includes inner layer around and pack polytetrafluoroethylene tape layer and outer layer aramid fiber braiding layer. The cable can maintain good flexibility, and also has stable and reliable electrical performance and mechanical performance in high-temperature environment, realize long-term stable operation.

Description

Technical Field

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

[0002] In modern industrial production and specialized applications such as metallurgy, chemical engineering, power generation, and aerospace, equipment operating environments often involve high temperatures and complex wiring. This necessitates cables that not only possess excellent high-temperature resistance to ensure normal power and signal transmission under high-temperature conditions and prevent insulation failure and conductor performance degradation, but also good flexibility to adapt to complex installation environments and frequent bending operations, facilitating cable laying and use. However, currently available high-temperature resistant cables generally have shortcomings. Some high-temperature resistant cables utilize materials and structures that result in poor flexibility, making them difficult to bend into the required shape during installation. Frequent bending can easily lead to conductor breakage and insulation damage, severely impacting cable lifespan and electrical performance. Conversely, some cables with better flexibility experience rapid deterioration of their insulation materials and other components under high-temperature environments, failing to meet the requirements for long-term stable operation. Utility Model Content

[0003] The purpose of this invention is to provide a flexible high-temperature resistant cable that solves the problem that existing high-temperature resistant cables cannot simultaneously achieve both flexibility and high-temperature resistance. This allows the cable to maintain good flexibility while possessing stable and reliable electrical and mechanical properties in high-temperature environments, enabling long-term stable operation.

[0004] The objective of this utility model is achieved through the following technical solution:

[0005] A flexible high-temperature resistant cable, comprising:

[0006] The conductor is made of nickel-plated copper alloy wire twisted in two layers. The twist pitch of the inner conductor is smaller than that of the outer conductor, and the twisting directions of the inner and outer conductors are opposite.

[0007] An insulating layer is disposed on the outside of the conductor, the insulating layer comprising an inner layer of high-temperature resistant mica tape and an outer layer of extruded silicone rubber;

[0008] A copper wire braided shielding layer is provided on the outside of the insulating layer, wherein the copper wires in the copper wire braided shielding layer are tin-plated.

[0009] A filler layer that fills the gaps in the stranding of the conductors;

[0010] An outer sheath is disposed outside the copper wire braided shielding layer. The outer sheath includes an inner layer of polytetrafluoroethylene tape and an outer layer of aramid fiber braid.

[0011] Furthermore, the inner conductor is formed by spirally twisting multiple strands of nickel-plated copper alloy wire at a pitch of 8-12 mm, and the outer conductor is formed by mesh braiding and twisting nickel-plated copper alloy wire at a pitch of 15-20 mm outside the inner conductor.

[0012] The inner conductor has a nickel-copper alloy wire with a fineness of 0.15-0.25 mm, and the outer conductor has a nickel-copper alloy wire with a fineness of 0.1-0.15 mm.

[0013] Furthermore, the inner conductor is formed by spirally twisting multiple strands of nickel-plated copper alloy wire at a pitch of 6-8 mm, and the outer conductor is formed by mesh braiding and twisting nickel-plated copper alloy wire at a pitch of 20-25 mm outside the inner conductor.

[0014] The inner conductor has a nickel-copper alloy wire with a fineness of 0.05-0.1 mm, and the outer conductor has a nickel-copper alloy wire with a fineness of 0.03-0.08 mm.

[0015] Furthermore, the inner conductor is formed by spirally twisting multiple strands of nickel-plated copper alloy wire at a pitch of 10-14 mm, and the outer conductor is formed by mesh braiding and twisting nickel-plated copper alloy wire at a pitch of 12-16 mm outside the inner conductor.

[0016] The inner conductor has a nickel-copper alloy wire with a fineness of 0.3-0.5 mm, and the outer conductor has a nickel-copper alloy wire with a fineness of 0.2-0.3 mm.

[0017] Furthermore, in the high-temperature resistant mica tape layer, the thickness of the high-temperature resistant mica tape is 0.05-0.15mm, the number of wrapping layers is 3-5, and the wrapping overlap rate is controlled at 50%-60%; the thickness of the silicone rubber layer is 0.5-1.5mm.

[0018] Furthermore, the thickness of the copper wire braided shielding layer is 0.2-0.5 mm, and the braiding density is not less than 80%.

[0019] Furthermore, in the polytetrafluoroethylene tape layer, the thickness of the polytetrafluoroethylene tape is 0.08-0.2 mm, the wrapping angle is set to 45°-60°, and the overlap rate is controlled at 40%-50%.

[0020] Furthermore, the thickness of the aramid fiber braided layer is 0.3-0.8 mm, and the braiding density is 12-18 stitches per centimeter.

[0021] Furthermore, the filling layer is ceramic fiber cotton or high-temperature silicone filling rope.

[0022] Furthermore, the outer side of the aramid fiber braided layer is coated with a waterproof coating, the thickness of which is 10-50 μm.

[0023] The beneficial effects of this utility model are:

[0024] This invention utilizes a series of high-temperature resistant materials and structural designs, including a nickel-plated copper alloy wire conductor, a double-layer insulation structure of mica tape and silicone rubber, a tin-plated copper wire shielding layer, a high-temperature resistant filling layer, and a double-layer outer sheath of polytetrafluoroethylene and aramid fiber. The synergistic effect of each layer effectively blocks heat transfer to the conductor, maintains the electrical performance of the conductor, and ensures that the insulation layer, shielding layer, and outer sheath do not degrade at high temperatures, thus meeting the requirements for use in high-temperature environments.

[0025] This utility model adopts a conductor structure with multi-strand fine nickel-plated copper alloy wires twisted in layers, combined with a flexible silicone rubber insulation layer, a high-temperature resistant flexible filling layer, and an outer sheath of aramid fiber with a reasonable braiding density, which gives the cable excellent bending performance and makes it less prone to breakage or performance degradation, greatly improving the flexibility and convenience of cable use.

[0026] This invention uses nickel-plated copper alloy wire conductors, which have low resistance characteristics and can effectively reduce power loss during power transmission. The double-layer insulation structure of mica tape and silicone rubber, as well as the tin-plated copper wire shielding layer, work together to ensure that the cable has high insulation performance under normal operation and high temperature environment, effectively blocking current leakage, ensuring the stability and safety of power transmission, and reducing the probability of electrical faults.

[0027] The chemical stability of polytetrafluoroethylene and the high strength and wear resistance of aramid fibers in this invention give the cable excellent anti-aging and anti-corrosion properties. In harsh working environments, the cable can maintain stable performance over a long period, extending its service life. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the structure of the flexible high-temperature resistant cable in Example 1.

[0029] Figure label:

[0030] 10-Inner conductor; 20-Outer conductor; 30-High temperature resistant mica tape layer; 40-Silicone rubber layer; 50-Copper wire braided shielding layer; 60-Filling layer; 70-PTFE tape layer; 80-Aramid fiber braided layer; 90-Waterproof coating. Detailed Implementation

[0031] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0032] In the description of this utility model, it should be noted that the terms "vertical direction," "up," "down," and "horizontal," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, "first," "second," "third," and "fourth" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or a connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0034] Example 1

[0035] This embodiment provides a flexible high-temperature resistant cable for use in conventional industrial scenarios, such as metallurgy and chemical industries. The cable needs to meet medium current carrying capacity requirements (e.g., rated current 100-300A) and also needs to adapt to a certain degree of bending and stretching.

[0036] like Figure 1 As shown, in this embodiment, a flexible high-temperature resistant cable includes:

[0037] The conductor is made of nickel-plated copper alloy wire twisted in two layers. The twist pitch of the inner conductor 10 is smaller than that of the outer conductor 20, and the twisting directions of the inner conductor 10 and the outer conductor 20 are opposite.

[0038] An insulating layer is disposed on the outside of the conductor. The insulating layer includes an inner layer of high-temperature resistant mica tape 30 and an outer layer of extruded silicone rubber 40.

[0039] A copper wire braided shielding layer 50 is disposed on the outside of the insulation layer, and the copper wires in the copper wire braided shielding layer 50 are tin-plated.

[0040] Filler layer 60 is used to fill the gaps between conductor strands;

[0041] An outer sheath is disposed outside the copper wire braided shielding layer 50. The outer sheath includes an inner layer of polytetrafluoroethylene tape 70 and an outer layer of aramid fiber braided layer 80. The outer side of the aramid fiber braided layer 80 is coated with a waterproof coating 90.

[0042] In this embodiment, the inner conductor 10 is formed by spirally twisting multiple strands of nickel-plated copper alloy wire at a pitch of 10 mm. The fineness of the nickel-plated copper alloy wire is 0.2 mm. The relatively thick inner copper wire provides stable structural support, ensuring that the cable is not easily broken under mechanical stresses such as tension and torsion. The outer conductor 20 is formed by mesh-braiding nickel-plated copper alloy wire at a pitch of 18 mm outside the inner conductor 10. The fineness of the nickel-plated copper alloy wire is 0.12 mm. The relatively thin outer copper wire makes it easier for the strands to slide relative to each other when the conductor is bent, enhancing the flexibility of the cable. Through this layered stranding structure, good conductivity is ensured while taking into account both the flexibility and mechanical strength of the cable.

[0043] Mica tape is inherently brittle, and a single layer cannot achieve complete sealing and high-temperature resistance. It requires 3-5 layers (with an overlap of 50%-60%) to form a seamless protective layer. In this embodiment, the inner insulating layer uses 0.1mm thick high-performance mica tape, with 4 layers and an overlap of 55% to ensure good insulation and heat insulation effects. The outer insulating layer uses 0.8mm thick silicone rubber, with a long-term operating temperature range of -60℃ to 200℃. Within this temperature range, the insulation resistance is not less than 100MΩ, providing reliable insulation protection for the cable.

[0044] In this embodiment, the shielding layer is made of tin-plated copper wire with a braiding density of 85% and a thickness of 0.3mm, which effectively shields external electromagnetic interference and ensures the stability of power transmission.

[0045] In this embodiment, the filler layer 60 is made of ceramic fiber cotton, which is used to fill the gaps between the conductors. The filling is tight, serving to buffer and stabilize the internal structure. During the conductor stranding process, these pre-formed filler materials are placed at specific positions on the stranding equipment. As the conductors are stranded, the filler materials naturally embed into the gaps, ensuring the accuracy and stability of the filling and preventing displacement during subsequent processing and use.

[0046] In this embodiment, in the outer sheath, the polytetrafluoroethylene (PTFE) tape layer has a thickness of 0.1 mm, a wrapping angle of 45°, and an overlap rate of 45%. The core function of the PTFE tape layer 70 is to assist the outer sheath in forming a stable structure, while also possessing certain chemical resistance and insulation properties. Its function depends on the "tight fit" and "structural stability" after wrapping, preventing wrinkles or loosening during the weaving of the outer aramid fibers. The defined wrapping angle ensures tight wrapping while balancing tensile stress and fit, thus guaranteeing the structural stability of the outer sheath.

[0047] Aramid fibers have a relatively large diameter (typically 0.5-1mm) and need to maintain a certain degree of elasticity after weaving. If a percentage density is used to limit the density, it may lead to an excessive pursuit of coverage at the expense of flexibility. Therefore, controlling the number of stitches ensures both strength and cable flexibility. The aramid fiber braided layer 80 has a thickness of 0.5mm and a braiding density of 15 stitches per centimeter, giving the cable good abrasion resistance, tensile strength, and tear resistance while maintaining a certain degree of flexibility.

[0048] Example 2

[0049] This embodiment provides a flexible high-temperature resistant cable for use in precision electronic equipment scenarios, such as aerospace and high-end instruments, where the cable must meet the requirements of complex wiring.

[0050] The cable structure in this embodiment is the same as that in embodiment 1, except that:

[0051] In this embodiment, the inner conductor 10 is formed by spirally twisting multiple strands of nickel-plated copper alloy wire at a pitch of 8 mm, and the fineness of the nickel-plated copper alloy wire is 0.08 mm; the outer conductor 20 is formed by mesh braiding and twisting nickel-plated copper alloy wire at a pitch of 22 mm outside the inner conductor 10, and the fineness of the nickel-plated copper alloy wire is 0.05 mm.

[0052] In this embodiment, the inner insulating layer is made of high-performance mica tape with a thickness of 0.08mm, with 3 wrapping layers and a wrapping overlap rate controlled at 50%; the outer insulating layer is made of silicone rubber with a thickness of 0.6mm, with a long-term operating temperature range of -60℃ to 180℃, and an insulation resistance of not less than 80MΩ within this temperature range.

[0053] In this embodiment, the braiding density of the tin-plated copper wire braided shielding layer 50 is 88%, and the thickness is 0.25mm, which effectively shields electromagnetic interference and meets the strict requirements of precision electronic equipment for signal transmission stability.

[0054] In this embodiment, the filler layer 60 is filled with high-temperature silicone filler rope at the conductor strand gap. After filling, the internal structure of the cable is stable and does not affect the flexibility of the cable.

[0055] In this embodiment, in the outer sheath, the PTFE tape layer 70 has a thickness of 0.08 mm, a wrapping angle of 50°, and an overlap rate of 40%; the aramid fiber braided layer 80 has a thickness of 0.4 mm and a braiding density of 16 stitches per centimeter. While ensuring protective performance, the outer diameter of the cable is minimized to adapt to the space constraints of precision equipment.

[0056] Example 3

[0057] This embodiment provides a flexible high-temperature resistant cable for high-current transmission scenarios. For high-current (rated current above 500A) applications such as power transmission and charging piles, the cable needs to have sufficient current carrying capacity and good heat dissipation performance.

[0058] The cable structure in this embodiment is the same as that in embodiment 1, except that:

[0059] In this embodiment, the inner conductor 10 is formed by spirally twisting multiple strands of nickel-plated copper alloy wire at a pitch of 12 mm. The fineness of the nickel-plated copper alloy wire is 0.4 mm, providing a solid conductive foundation for the conductor. The outer conductor 20 is formed by mesh-braiding and twisting nickel-plated copper alloy wire at a pitch of 14 mm outside the inner conductor 10. The fineness of the nickel-plated copper alloy wire is 0.3 mm. The combination of thicker copper wires can carry large currents, and the multi-strand twisting is beneficial for heat dissipation, reducing the temperature rise of the cable when a large current passes through.

[0060] In this embodiment, the inner insulating layer uses a high-performance mica tape with a thickness of 0.12mm, with 5 wrapping layers and a wrapping overlap rate controlled at 60%; the outer insulating layer uses silicone rubber with a thickness of 1.2mm, with a long-term operating temperature range of -60℃ to 220℃, and an insulation resistance of not less than 120MΩ within this temperature range, ensuring insulation reliability under high current and high temperature environments.

[0061] In this embodiment, the tin-plated copper wire braided shielding layer 50 has a braiding density of 90% and a thickness of 0.4mm, effectively shielding electromagnetic interference generated by high current while ensuring the stability of the shielding layer itself.

[0062] In this embodiment, the filling layer 60 is made of ceramic fiber cotton and filled into the gaps between the conductor strands. The filling is tight, which not only ensures the stability of the cable structure, but also helps to dissipate heat.

[0063] In this embodiment, in the outer sheath, the PTFE tape layer 70 has a thickness of 0.15mm, a wrapping angle of 60°, and an overlap rate of 50%; the aramid fiber braided layer 80 has a thickness of 0.6mm and a braiding density of 14 stitches per centimeter, which gives the cable strong mechanical strength, enabling it to withstand the tension and vibration that may occur during high current transmission, while maintaining a certain degree of flexibility for easy installation.

[0064] In Examples 1, 2, and 3, the outer side of the aramid fiber braided layer 80 is coated with a 30μm thick waterproof coating 90. This coating is constructed using low surface energy materials such as fluoropolymers and siloxanes, along with nano-sized silica particles. The low surface energy materials reduce the surface free energy of the coating, while the nanoparticles create a rough structure that increases the contact angle between water and the surface, causing water droplets to form spherical shapes and roll off. This not only provides waterproofing but also reduces dirt adhesion, achieving a self-cleaning function. It effectively prevents moisture from penetrating into the cable, improves the cable's moisture resistance, and extends its service life.

[0065] The above description merely illustrates the preferred technical solution of this utility model, and while the description is relatively specific and detailed, it should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and this utility model also intends to include these modifications and variations.

Claims

1. A flexible high-temperature resistant cable, characterized in that: include: The conductor is made of nickel-plated copper alloy wire twisted in two layers. The twist pitch of the inner conductor is smaller than that of the outer conductor, and the twisting directions of the inner and outer conductors are opposite. An insulating layer is disposed on the outside of the conductor, the insulating layer comprising an inner layer of high-temperature resistant mica tape and an outer layer of extruded silicone rubber; A copper wire braided shielding layer is provided on the outside of the insulating layer, wherein the copper wires in the copper wire braided shielding layer are tin-plated. A filler layer that fills the gaps in the stranding of the conductors; An outer sheath is disposed outside the copper wire braided shielding layer. The outer sheath includes an inner layer of polytetrafluoroethylene tape and an outer layer of aramid fiber braid.

2. The flexible high-temperature resistant cable according to claim 1, characterized in that: The inner conductor is formed by spirally twisting multiple strands of nickel-plated copper alloy wire at a pitch of 8-12 mm, and the outer conductor is formed by mesh-braiding and twisting nickel-plated copper alloy wire at a pitch of 15-20 mm outside the inner conductor. The inner conductor has a nickel-copper alloy wire with a fineness of 0.15-0.25 mm, and the outer conductor has a nickel-copper alloy wire with a fineness of 0.1-0.15 mm.

3. The flexible high-temperature resistant cable according to claim 1, characterized in that: The inner conductor is formed by spirally twisting multiple strands of nickel-plated copper alloy wire at a pitch of 6-8 mm, and the outer conductor is formed by mesh-braiding and twisting nickel-plated copper alloy wire at a pitch of 20-25 mm outside the inner conductor. The inner conductor has a nickel-copper alloy wire with a fineness of 0.05-0.1 mm, and the outer conductor has a nickel-copper alloy wire with a fineness of 0.03-0.08 mm.

4. The flexible high-temperature resistant cable according to claim 1, characterized in that: The inner conductor is formed by spirally twisting multiple strands of nickel-plated copper alloy wire at a pitch of 10-14 mm, and the outer conductor is formed by mesh braiding and twisting nickel-plated copper alloy wire at a pitch of 12-16 mm outside the inner conductor. The inner conductor has a nickel-copper alloy wire with a fineness of 0.3-0.5 mm, and the outer conductor has a nickel-copper alloy wire with a fineness of 0.2-0.3 mm.

5. The flexible high-temperature resistant cable according to claim 1, characterized in that: In the high-temperature resistant mica tape layer, the thickness of the high-temperature resistant mica tape is 0.05-0.15mm, the number of wrapping layers is 3-5, and the wrapping overlap rate is controlled at 50%-60%; the thickness of the silicone rubber layer is 0.5-1.5mm.

6. The flexible high-temperature resistant cable according to claim 1, characterized in that: The thickness of the copper wire braided shielding layer is 0.2-0.5 mm, and the braiding density is not less than 80%.

7. The flexible high-temperature resistant cable according to claim 1, characterized in that: In the polytetrafluoroethylene (PTFE) tape layer, the thickness of the PTFE tape is 0.08-0.2 mm, the wrapping angle is set to 45°-60°, and the overlap rate is controlled at 40%-50%.

8. The flexible high-temperature resistant cable according to claim 1, characterized in that: The thickness of the aramid fiber braided layer is 0.3-0.8 mm, and the braiding density is 12-18 stitches per centimeter.

9. The flexible high-temperature resistant cable according to claim 1, characterized in that: The filling layer is ceramic fiber cotton or high-temperature silicone filling rope.

10. The flexible high-temperature resistant cable according to any one of claims 1 to 9, characterized in that: The outer side of the aramid fiber braided layer is coated with a waterproof coating, the thickness of which is 10-50 μm.

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