Aluminum armored light weight cable and armored protector matched therewith

Abstract

The utility model relates to wire and cable technical field, concretely relates to a kind of aluminium armoured lightweight cable and the armoured protector matched with it, including aluminium alloy conductor and buffer structure, the aluminium alloy conductor is wrapped by XLPE insulation layer, and aluminium alloy conductor and buffer structure are embedded in honeycomb cover, the outer surface of honeycomb cover is provided with spiral wrapping tape, the outer surface of spiral wrapping tape is provided with self-locking alloy armouring.The utility model can adopt "aluminium alloy conductor-buffer structure-honeycomb cover" co-extrusion forming design, eliminate interlayer sliding risk;The hexagonal through structure of honeycomb cover disperses the stress concentration of traditional cable into multi-path transmission, significantly reduces local stress concentration coefficient, avoids the structural damage caused by stress concentration.

Description

Technical Field

[0001] This utility model relates to the field of wire and cable technology, specifically to an aluminum armored lightweight cable and its matching armored protective device. Background Technology

[0002] In the field of wire and cable technology, traditional cast aluminum explosion-proof junction boxes and distribution boxes often lack suitable live-joint structural connection designs when used with various wires and cables. This results in the external threaded conduit and the cable protective layer not being able to achieve a tight fit. This defect not only directly weakens the mechanical stability of the explosion-proof wiring conduit, but may also cause spark leakage or gas infiltration due to assembly gaps, becoming the core cause of major safety hazards.

[0003] Secondly, for the specific scenario of armored cables with shielding mesh, existing technologies reveal a more prominent contradiction: the contact quality between the shielding mesh and the armor ring directly affects the electromagnetic shielding effectiveness. When the contact between the two is poor, the electromagnetic waves generated by adjacent electromechanical equipment cannot be effectively attenuated, and instead will cause mutual interference through the unshielded gaps, which will exacerbate the risk of electromagnetic pollution.

[0004] Therefore, it is necessary to invent an aluminum armored lightweight cable and its matching armored protector to solve the above problems. Utility Model Content

[0005] The purpose of this invention is to provide an aluminum armored lightweight cable and its matching armored protector. It adopts a co-extrusion design of "aluminum alloy conductor-buffer structure-honeycomb sleeve" to eliminate the risk of interlayer slippage. The hexagonal through-structure of the honeycomb sleeve disperses the concentrated stress of traditional cables into multiple paths, significantly reducing the local stress concentration coefficient and avoiding structural damage caused by stress concentration. Simultaneously, the grooves on the outer surface of the honeycomb sleeve are interference-fitted with springs, providing continuous contact pressure to compensate for thermal expansion and contraction caused by temperature changes, preventing long-term loosening and failure of the joint. This design solves the problem of insufficient tight fit between the external threaded conduit and the cable protective layer. The armored protector employs a three-level shielding design of "upper shielding ring-alloy gasket-lower shielding ring": the upper shielding ring absorbs some high-frequency components; the alloy gasket dissipates some mid-frequency energy through eddy currents; and the lower shielding ring filters out the remaining low-frequency components, solving the electromagnetic interference problem caused by poor contact between the shielding mesh and the armoring ring.

[0006] To achieve the above objectives, this utility model provides the following technical solution: it includes an aluminum alloy conductor and a buffer structure, wherein the aluminum alloy conductor is wrapped with an XLPE insulation layer, and the aluminum alloy conductor and the buffer structure are embedded in a honeycomb sleeve, the outer surface of the honeycomb sleeve is provided with a wrapping tape, and the outer surface of the wrapping tape is provided with a self-locking alloy armor; wherein, the honeycomb sleeve is provided with a hexagonal structure, which can increase its own strength.

[0007] Preferably, a groove is pre-formed on the outer surface of the honeycomb sleeve, and a spring is sleeved in the groove.

[0008] Preferably, the spring is made of titanium-aluminum-vanadium alloy.

[0009] Preferably, the spring is made of 60Si2MnA spring steel.

[0010] Preferably, the hexagonal structure of the honeycomb sleeve extends through the surface of the honeycomb sleeve.

[0011] Preferably, the buffer structure is rope-like cross-linked polyethylene microporous foam.

[0012] Preferably, water-resistant powder is added to the buffer structure.

[0013] This utility model also provides an armored protector for use with aluminum armored lightweight cables, including a nut and a sealing ring. From bottom to top, the nut and sealing ring consist of a connector base, a shielding device, a sealing device, and a support frame. From top to bottom, the shielding device includes an upper shielding ring, a lower shielding ring, and an alloy gasket.

[0014] Preferably, the alloy gasket is sandwiched between the upper shielding ring and the lower shielding ring, and the sealing device consists of a Cu-Al-Ni alloy layer, a silicone rubber matrix, and a fluororubber protective layer from the inside out.

[0015] The technical effects and advantages provided by this utility model in the above technical solution are as follows: The outer surface of the honeycomb sleeve is provided with a wrapping tape, and the outer surface of the wrapping tape is provided with a self-locking alloy armor. The wrapping tape provides transition layer protection and radial restraint. The self-locking alloy armor provides a mechanical protective layer. Furthermore, the aluminum alloy conductor and the buffer structure are embedded in the honeycomb sleeve to form a co-extrusion molding of aluminum alloy conductor-buffer structure-honeycomb sleeve, which helps to eliminate interlayer slippage in conventional technologies. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0017] Figure 1 This is a perspective view of Embodiment 1 of the present utility model; Figure 2 This is a side view of Embodiment 1 of the present invention without the spring; Figure 3 This is a perspective view of Embodiment 2 of the present invention; Figure 4This is a side view of Embodiment 2 of the present invention; Explanation of reference numerals in the attached figures: 100. Aluminum alloy conductor; 200. Buffer structure; 300. XLPE insulation layer; 400. Honeycomb sleeve; 500. Wrapping tape; 600. Self-locking alloy armor; 700. Groove; 800. Spring; 900. Nut; 901. Connector base; 902. Shielding device; 903. Sealing device; 904. Support frame; 905. Sealing ring; 912. Upper shielding ring; 913. Lower shielding ring; 914. Alloy gasket. Detailed Implementation

[0018] To enable those skilled in the art to better understand the technical solution of this utility model, the present utility model will be further described in detail below with reference to the accompanying drawings.

[0019] Example 1: This utility model provides the following... Figure 1-2 The illustrated aluminum armored lightweight cable includes an aluminum alloy conductor 100 and a buffer structure 200. The aluminum alloy conductor 100 is made of 6101-T6 aluminum alloy and serves as the main channel for power transmission. Its surface is anodized (oxide film thickness 15μm-20μm). This design achieves corrosion resistance superior to traditional steel tape. The aluminum alloy conductor 100 is wrapped with an XLPE insulation layer 300, which provides insulation protection for the aluminum alloy conductor 100.

[0020] Furthermore, the aluminum alloy conductor 100 and the buffer structure 200 are embedded in the honeycomb sleeve 400. The function of the buffer structure 200 is to buffer mechanical stress and fill the gaps between the aluminum alloy conductor 100. The honeycomb sleeve 400 is provided with a hexagonal structure, which can increase its own strength. The honeycomb sleeve 400 adopts a hexagonal through-hole design (the diameter of the through hole is 3mm~5mm).

[0021] The outer surface of the honeycomb sleeve 400 is provided with a wrapping tape 500, and the outer surface of the wrapping tape 500 is provided with a self-locking alloy armor 600; the wrapping tape 500 can provide transition layer protection and radial restraint. The self-locking alloy armor 600 provides a mechanical protection layer.

[0022] Furthermore, the aluminum alloy conductor 100 and the buffer structure 200 are embedded in the honeycomb sleeve 400. This is to form a structure in which the aluminum alloy conductor 100, the buffer structure 200, and the honeycomb sleeve 400 are co-extruded, which helps to eliminate interlayer slippage in the conventional prior art.

[0023] A groove 700 is pre-formed on the outer surface of the honeycomb sleeve 400, and a spring 800 is fitted inside the groove 700. The groove 700 and the spring 800 are interference-fitted (interference amount 0.05mm-0.2mm), forming a mechanical complement to the honeycomb structure (that is, enabling multi-path transmission of stress waves). The interference fit between the groove 700 on the outer surface of the honeycomb sleeve 400 and the spring 800 provides continuous contact pressure and also realizes the damping consumption of the buffer material. The honeycomb structure can prevent cell wall buckling instability, compensate for the thermal expansion and contraction of the material caused by temperature changes, and prevent long-term loosening and failure of the joint. This design solves the problem caused by the inability to achieve a tight fit between the external threaded tubing and the cable protection layer. The design scheme of embedding the buffer structure 200 into the honeycomb sleeve 400 achieves the following: the hexagonal through-structure of the honeycomb sleeve 400 disperses the concentrated stress of the traditional cable into multi-path transmission, avoids structural damage caused by stress concentration, and can prevent permanent deformation of this application.

[0024] The spring 800 is made of titanium-aluminum-vanadium alloy. This design can continuously provide a contact pressure of 15-20N during cable operation, thereby compensating for the thermal expansion and contraction of materials due to temperature changes. This prevents the joint from loosening and failing due to long-term thermal expansion and contraction.

[0025] The hexagonal structure of the honeycomb sheath 400 extends throughout its surface. This hexagonal topology disperses the concentrated stress of traditional cables into multiple pathways, reducing the local stress concentration coefficient. The through-holes create an air permeability of 0.05 m³ / (h·m), balancing the pressure difference between the inside and outside of the cable and preventing sheath bulging or collapse due to temperature changes. The air layer formed by the honeycomb sheath 400 also reduces the overall thermal conductivity, offering a significant advantage in thermal conductivity compared to a solid structure.

[0026] The buffer structure 200 is a rope-like cross-linked polyethylene microporous foam. The spirally arranged rope-like structure provides axial compressive strength (higher than existing block foams), while maintaining a radial flexibility of 5MPa-6MPa, achieving multi-dimensional protection against tension, compression, and torsion. This design converts mechanical impact energy into plastic deformation of the foam wall and airflow friction. Water-blocking powder (specifically nano-SiO2 water-blocking powder) is added to the buffer structure 200. Upon contact with water, the nano-SiO2 water-blocking powder undergoes a swelling reaction, rapidly blocking the interconnected pores in the foam. When microcracks appear in the buffer layer, the water-blocking powder migrates with the water to the damaged area and expands, automatically filling cracks 0.1mm-0.3mm wide. Furthermore, the amino groups modified on the powder surface neutralize H⁺ or OH⁻ in the permeating water, stabilizing the pH value within the range of 6.5-7.5, preventing acid and alkali corrosion of metal components. To avoid abrupt changes in cable diameter, the wrapping tape 500 avoids the groove 700 during wrapping.

[0027] Example 2: The difference between this example and Example 1 is that the spring 800 is made of 60Si2MnA spring 800 steel, which is a lower cost design. When the cable is subjected to abnormal tension, this design can absorb the impact energy through controllable plastic deformation (ε≈2%-3%), thus avoiding damage to the conductor insulation layer.

[0028] The other design schemes in this embodiment are the same as those in Embodiment 1.

[0029] Example 3: As Figure 3-4 As shown, this embodiment provides an armored protector that is compatible with the aluminum armored lightweight cable in Embodiment 1. The difference between this embodiment and Embodiment 1 is that this embodiment includes a nut 900 and a sealing ring 905. From bottom to top, the nut 900 and the sealing ring 905 are a connector base 901, a shielding device 902, a sealing device 903, and a support frame 904. The shielding device 902 includes an upper shielding ring 912, a lower shielding ring 913, and an alloy gasket 914 from top to bottom.

[0030] The upper shielding ring 912 is made of 99.9% pure copper with a thickness of 1.2mm ± 0.1mm. The surface of the upper shielding ring 912 is tin-plated (with a thickness of 2μm-3μm).

[0031] The lower shielding ring 913 is specifically made of copper-nickel alloy (Cu90Ni10) with a thickness of 1.0±0.1mm. The alloy gasket 914 is specifically made of Cu-Al-Ni ternary alloy (85:10:5), where 85:10:5 specifically refers to a weight percentage ratio of 85% copper (Cu), 10% aluminum (Al), and 5% nickel (Ni) with a thickness of 0.5mm±0.05mm. This design can suppress short-circuit electromagnetic pulses. The first stage: the copper layer of the upper shielding ring 912 absorbs 30-40% of the high-frequency components; the second stage: the eddy currents of the alloy gasket 914 dissipate 40%-50% of the mid-frequency energy; the third stage: the nickel alloy layer of the lower shielding ring 913 filters out the remaining low frequencies. This design solves the electromagnetic interference problem caused by poor contact between the shielding mesh and the armor ring, avoiding the risk of electromagnetic pollution.

[0032] The alloy gasket 914 is sandwiched between the upper shielding ring 912 and the lower shielding ring 913. The sealing device 903 consists of a Cu-Al-Ni alloy layer, a silicone rubber matrix, and a fluororubber protective layer from the inside out. The Cu-Al-Ni alloy layer (0.1mm~0.3mm) provides a metal plastic deformation seal, the silicone rubber matrix (0.5mm~0.7mm) achieves an elastic compensation seal, and the fluororubber layer (0.3mm~0.5mm) forms a chemical inert protection.

[0033] This design also features dynamic adaptability. Specifically, the three-layer structure of the sealing device 903 maintains interface micro-motion below 0.01mm under vibration environments of 10Hz-50Hz, and the coefficient of friction remains stable between 0.2 and 0.3, preventing wear and heat generation. If necessary for production, the armored protector provided in this embodiment can also be installed with other types of cables.

[0034] The other design schemes in this embodiment are the same as those in Embodiment 1.

[0035] The width and thickness of the wrapping tape 500 and spring 800 in the attached drawings are for illustrative purposes only, and those skilled in the art can adjust them according to the actual situation.

[0036] The foregoing description only illustrates certain exemplary embodiments of the present invention. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A lightweight aluminum armored cable, comprising an aluminum alloy conductor and a buffer structure, characterized in that, The aluminum alloy conductor is wrapped with an XLPE insulation layer, and the aluminum alloy conductor and the buffer structure are embedded in the honeycomb sleeve. The outer surface of the honeycomb sleeve is provided with a wrapping tape, and the outer surface of the wrapping tape is provided with a self-locking alloy armor. The honeycomb sleeve is provided with a hexagonal structure, which can increase its own strength.

2. The aluminum armored lightweight cable as described in claim 1, characterized in that, The outer surface of the honeycomb sleeve has a pre-formed groove, and a spring is fitted inside the groove.

3. The aluminum armored lightweight cable as described in claim 2, characterized in that, The spring is made of titanium-aluminum-vanadium alloy.

4. The aluminum armored lightweight cable as described in claim 2, characterized in that, The spring is made of 60Si2MnA spring steel.

5. The aluminum armored lightweight cable as described in claim 2, characterized in that, The hexagonal structure of the honeycomb sleeve extends through the surface of the honeycomb sleeve.

6. The aluminum armored lightweight cable as described in claim 1, characterized in that, The buffer structure is a rope-like cross-linked polyethylene microporous foam.

7. An armored protective device for use with any of the aluminum armored lightweight cables described in claims 1-6, comprising a nut and a sealing ring, characterized in that, From bottom to top, the components between the nut and the sealing ring are the connector base, the shielding device, the sealing device, and the support frame. The shielding device, from top to bottom, includes an upper shielding ring, a lower shielding ring, and an alloy gasket.

8. The armored protective device as described in claim 7, characterized in that, The alloy gasket is sandwiched between the upper and lower shielding rings, and the sealing device consists of a Cu-Al-Ni alloy layer, a silicone rubber matrix, and a fluororubber protective layer from the inside out.

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