A profiled conductor structure for a flexible cable

Abstract

The utility model provides a special-shaped conductor structure of flexible cable, including flexible center layer, inner layer sector conductor, middle layer sector conductor and outer layer sector conductor which are coaxially arranged from inside to outside, the flexible center layer includes the stranding of the plurality of soft copper wire, and the inner buffer layer is arranged between the inner layer sector conductor and the middle layer sector conductor, and the outer buffer layer is arranged between the middle layer sector conductor and the outer layer sector conductor, and the utility model solves the technical problem that provides a special-shaped conductor structure of flexible cable, solves the problem of traditional special-shaped wire core conductor although having more conductor area on the same cross -sectional area to realize higher conductivity efficiency, but not easy to bend, the problem of big curvature radius after bending.

Description

Technical Field

[0001] This utility model relates to the field of power cable technology, and in particular to an irregularly shaped conductor structure for a flexible cable. Background Technology

[0002] Traditional irregular core conductor structures, such as Figure 3 As shown, the cable has a circular core in the middle, surrounded by multiple trapezoidal cores on the outside. Compared with the traditional circular stranded wire structure, this structure has a larger conductor area in the same cross-sectional area, resulting in higher conductivity. However, the cable with this core structure is not easy to bend, and the radius of curvature after bending is large. Summary of the Invention

[0003] The technical problem to be solved by this utility model is to provide a non-circular conductor structure for flexible cables, which solves the problem that although traditional non-circular conductors have more conductor area on the same cross-sectional area to achieve higher conductivity, they are not easy to bend and have a large radius of curvature after bending.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is: a flexible cable with an irregular conductor structure, including a flexible central layer, an inner fan-shaped conductor, a middle fan-shaped conductor and an outer fan-shaped conductor arranged coaxially from the inside to the outside. The flexible central layer is made of multiple strands of soft copper wire twisted together. An inner buffer layer is provided between the inner fan-shaped conductor and the middle fan-shaped conductor, and an outer buffer layer is provided between the middle fan-shaped conductor and the outer fan-shaped conductor.

[0005] Preferably, the inner buffer layer and the outer buffer layer are flexible mesh structures.

[0006] Preferably, the outer surfaces of the inner and middle fan-shaped conductors are provided with protrusions.

[0007] Preferably, the corners of the inner, middle, and outer fan-shaped conductors are all rounded.

[0008] Preferably, the flexible central layer includes a central soft copper wire and six soft copper wires arranged around the outside.

[0009] Preferably, the inner layer has 6 sector conductors, the middle layer has 9 sector conductors, and the outer layer has 12 sector conductors.

[0010] Preferably, the inner and outer buffer layers are made of EVA material.

[0011] This utility model provides an irregularly shaped conductor structure for a flexible cable, which has the following advantages: 1. The core layer adopts a flexible core consisting of "one central soft copper wire + six outer soft copper wires twisted together," replacing the traditional solid circular core. The soft copper wire itself has high elongation and strong deformation capability. The multi-strand twisted structure can disperse bending stress through the slight relative displacement between the copper wires, avoiding rigid resistance from the core layer and providing basic flexible support for the entire conductor. Interlayer buffer layers: Flexible mesh buffer layers made of EVA material are added between the inner and middle layers, and between the middle and outer fan-shaped conductors. The mesh structure combines elasticity and sliding space, absorbing interlayer compression during bending while allowing adjacent fan-shaped conductor layers to slide slightly along the surface of the buffer layer, significantly reducing bending resistance and solving the problem of "tight interlayer contact and mutual obstruction during bending" in traditional irregularly shaped conductors. Ultimately, this reduces the cable bending radius, adapting to complex wiring scenarios.

[0012] 2. Raised dots are set on the outer surface of the inner and middle layer fan-shaped conductors, which can penetrate the flexible buffer layer to form stable conductive contacts. Even if there is a buffer structure between the layers, the raised dots can still ensure smooth current transmission between the conductors of each layer, avoid the increase in contact resistance caused by interlayer isolation, and maintain the core advantages of traditional irregular conductors: "large conductor area per unit area and high conductivity".

[0013] 3. The corners of the inner, middle, and outer fan-shaped conductors are all designed with rounded corners, replacing the sharp corners of traditional irregularly shaped conductors. This avoids cracking and breakage at sharp points due to stress concentration during bending, extending the conductor's service life under repeated bending scenarios and reducing the risk of failure during long-term use. Attached Figure Description

[0014] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a schematic diagram of the structure of the buffer layer and the sector-shaped conductor of this utility model; Figure 3 This is a schematic diagram of the existing technology. Detailed Implementation

[0015] like Figure 1-2 As shown, a flexible cable with an irregularly shaped conductor structure includes a flexible central layer, an inner fan-shaped conductor 2, a middle fan-shaped conductor 3, and an outer fan-shaped conductor 4 arranged coaxially from the inside to the outside. The flexible central layer is composed of multiple strands of soft copper wire 1 twisted together. An inner buffer layer 5 is provided between the inner fan-shaped conductor 2 and the middle fan-shaped conductor 3, and an outer buffer layer 6 is provided between the middle fan-shaped conductor 3 and the outer fan-shaped conductor 4. Through the design of the flexible central layer and the interlayer buffer layers, the high conductivity of the irregularly shaped conductor is retained, while effectively solving the problems of traditional irregularly shaped conductors being difficult to bend and having a large bending radius, thus providing basic flexible support for the conductor.

[0016] Preferably, the inner buffer layer 5 and the outer buffer layer 6 are flexible mesh structures. Setting the buffer layers as flexible mesh structures enhances interlayer buffering and sliding performance to improve flexibility, while also maintaining lightweight design and not affecting subsequent conductive contact.

[0017] Preferably, the outer surfaces of the inner fan-shaped conductor 2 and the middle fan-shaped conductor 3 are provided with protrusions 7. Protrusions on the outer surfaces of the inner and middle fan-shaped conductors can penetrate the buffer layer to form stable conductive contacts, avoiding increased contact resistance due to interlayer isolation and ensuring high conductivity.

[0018] Preferably, the corners of the inner fan-shaped conductor 2, the middle fan-shaped conductor 3, and the outer fan-shaped conductor 4 are all rounded. Rounding the corners of each fan-shaped conductor layer avoids stress concentration at the corners during bending, reduces the risk of cracking and breakage, and improves the durability of the conductor.

[0019] Preferably, the flexible central layer includes a central soft copper wire and six soft copper wires arranged around the outside.

[0020] Preferably, the inner layer sector conductor 2 has 6 conductors, the middle layer sector conductor 3 has 9 conductors, and the outer layer sector conductor 4 has 12 conductors. This layered design of "6 conductors in the inner layer, 9 in the middle layer, and 12 in the outer layer" ensures the overall compactness of the conductors through an increasing number of conductors arranged in a ring, thus improving flexibility without reducing conductivity per unit cross-sectional area, achieving a balance between improved flexibility and high conductivity.

[0021] Preferably, the inner buffer layer 5 and the outer buffer layer 6 are made of EVA material. Using EVA material to make the buffer layer can meet the requirements of flexible buffering, balance cost and processability, and also ensure weather resistance and long-term structural stability.

[0022] This invention employs a layered structure coaxially arranged from the inside out, consisting of a flexible central layer, an inner fan-shaped conductor, a middle fan-shaped conductor, and an outer fan-shaped conductor, formed by twisting together a central soft copper wire and six outer soft copper wires. A flexible mesh buffer layer of EVA material is added between adjacent fan-shaped conductor layers. Protrusions are added to the outer sides of the inner and middle fan-shaped conductors, and the corners of each fan-shaped conductor layer are rounded. The number of fan-shaped conductors in the inner, middle, and outer layers is limited to 6, 9, and 12, respectively. This design significantly improves conductor flexibility and reduces bending difficulty while retaining the high conductivity of irregularly shaped conductors and avoiding stress concentration damage, thus achieving compatibility between flexibility and high conductivity.

[0023] The above embodiments are merely preferred technical solutions of this utility model and should not be considered as limitations on this utility model. The protection scope of this utility model should be the technical solution described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the protection scope of this utility model.

Claims

1. An irregularly shaped conductor structure for a flexible cable, characterized in that: It includes a flexible central layer, an inner fan-shaped conductor (2), a middle fan-shaped conductor (3) and an outer fan-shaped conductor (4) arranged coaxially from the inside to the outside. The flexible central layer is made of multiple strands of soft copper wire (1) twisted together. An inner buffer layer (5) is provided between the inner fan-shaped conductor (2) and the middle fan-shaped conductor (3), and an outer buffer layer (6) is provided between the middle fan-shaped conductor (3) and the outer fan-shaped conductor (4).

2. The irregular conductor structure of a flexible cable according to claim 1, characterized in that: The inner buffer layer (5) and the outer buffer layer (6) are flexible mesh structures.

3. The irregular conductor structure of a flexible cable according to claim 2, characterized in that: The outer surfaces of the inner fan-shaped conductor (2) and the middle fan-shaped conductor (3) are provided with protrusions (7).

4. The irregular conductor structure of a flexible cable according to claim 1, characterized in that: The corners of the inner fan-shaped conductor (2), the middle fan-shaped conductor (3), and the outer fan-shaped conductor (4) are all rounded.

5. The irregular conductor structure of a flexible cable according to claim 1, characterized in that: The flexible central layer includes a central soft copper wire and six soft copper wires arranged around the outside.

6. The irregular conductor structure of a flexible cable according to claim 1, characterized in that: The inner fan-shaped conductor (2) has 6 units, the middle fan-shaped conductor (3) has 9 units, and the outer fan-shaped conductor (4) has 12 units.

7. The irregular conductor structure of a flexible cable according to claim 1, characterized in that: The inner buffer layer (5) and the outer buffer layer (6) are made of EVA material.

Images