A seamless through ground wire

Abstract

This utility model discloses a seamless grounding wire, comprising a conductor layer, an anti-corrosion transition layer, a reinforcement layer, a wear-resistant layer, and a physical protective layer. The anti-corrosion transition layer, reinforcement layer, wear-resistant layer, and physical protective layer are coaxially composite arranged from the inside out and wrapped around the outer periphery of the conductor layer in a continuous tubular structure. The conductor layer of this utility model is made of high-purity electrolytic copper, with a single trapezoidal cross-section copper wire as the center and radially layered spirally twisted on the outside. The copper wires between the layers are interlaced and tightly bonded without gaps, increasing the conductive area, increasing the current carrying capacity, and allowing for faster discharge of fault current and lightning current. The anti-corrosion transition layer is a double-layer structure of a passivated inner layer and an outer skin layer, forming double protection to prevent localized corrosion. The reinforcement layer is continuously spirally wrapped with aluminum-plastic composite tape, which can form an additional anti-corrosion barrier. The wear-resistant layer is continuously extruded and bonded to the reinforcement layer, with raised textures on the outer periphery to reduce friction and improve wear resistance. The physical protective layer is made of a material with added ultraviolet absorbers, which can resist ultraviolet aging and embrittlement.

Description

Technical Field

[0001] This utility model mainly relates to the field of railway grounding technology, specifically a seamless through grounding wire. Background Technology

[0002] A railway ground wire is a conductor structure used in railway systems to provide a grounding channel for various facilities and equipment along the railway line that require grounding, such as buildings, power supply equipment, and signaling equipment.

[0003] Seamless grounding wires are a specific type of railway grounding wire, specifically referring to a highly conductive grounding conductor continuously laid along the entire railway line, which needs to be connected to all facilities and equipment along the line that require grounding. Existing conductor layers mostly use ordinary square or cylindrical copper wires, lacking proper cross-sectional fit, and the stranding process is disordered or single-layer stranding, failing to achieve precise radial arrangement and staggered positioning of the layers. This results in the copper wires not being able to tightly adhere to each other, forming gaps between strands, thus reducing the conductive area. Furthermore, the existing stranding process does not perform precise radial arrangement and staggered positioning of the copper wires in layers, only using simple disordered stranding or single-layer stranding, causing the copper wires to not be able to tightly adhere to each other, resulting in gaps between strands. Ultimately, this leads to a loose structure, and the use of a single anti-corrosion structure makes it prone to seams or gaps between layers due to discontinuous forming, resulting in weak protective capabilities and susceptibility to localized corrosion. Utility Model Content

[0004] This utility model addresses the problem that existing technical solutions are too simplistic by providing a seamless grounding wire. This solves the problems mentioned in the background section, such as the difficulty in achieving tight interlayer bonding when using ordinary round copper wires during stranding, and the weakness in protective capabilities caused by a single anti-corrosion structure resulting from discontinuous forming and gaps between layers.

[0005] The technical solution adopted by this utility model to solve the above-mentioned technical problems is as follows: A seamless through ground wire includes a conductor layer, an anti-corrosion transition layer, a reinforcement layer, a wear-resistant layer, and a physical protection layer. The anti-corrosion transition layer, the reinforcement layer, the wear-resistant layer, and the physical protection layer are coaxially arranged from the inside to the outside and wrapped around the outer periphery of the conductor layer in a continuous tubular structure. The whole extends along the railway to form a seamless through structure.

[0006] Furthermore, the conductor layer is formed by spirally twisting together a trapezoidal cross-section copper wire as the center and several trapezoidal cross-section copper wires distributed radially outward around the center. The copper wires of adjacent layers are staggered and tightly attached in the radial direction to form a seamless twisted structure. Each copper wire is coated with an anti-oxidation protective coating.

[0007] Furthermore, the anti-corrosion transition layer includes a passivation inner layer and an outer skin layer. The passivation inner layer is a dense film-like structure covering the outer peripheral surface of the conductor layer, and the outer skin layer is a continuous tubular structure that tightly covers the outer peripheral surface of the passivation inner layer.

[0008] Furthermore, the reinforcing layer is an aluminum-plastic composite strip structure, which is wrapped around the outer surface of the anti-corrosion transition layer in a continuous spiral wrapping manner.

[0009] Furthermore, the wear-resistant layer is fixedly connected to the outer surface of the reinforcing layer by continuous extrusion, and the outer peripheral surface of the wear-resistant layer has a plurality of raised textured structures evenly distributed.

[0010] Furthermore, the physical protective layer is coated on the outer periphery of the wear-resistant layer through a continuous extrusion process, and its outer periphery has a continuous and smooth shape.

[0011] Compared with the prior art, the beneficial effects of this utility model are as follows: 1. The conductor layer uses ≥99.95% high-purity electrolytic copper, employing a single trapezoidal cross-section copper wire as the center and an outer radially layered spiral stranded structure. This increases the conductive area and reduces impedance, resulting in higher current carrying capacity compared to existing ground wires. Fault current and lightning current discharge are also more rapid. Adjacent copper wires are interlaced and tightly bonded to form a seamless structure, avoiding the waste of conductive area and loose structure caused by gaps between strands in existing conductor layers. The anti-corrosion transition layer is a double-layer structure consisting of a passivation inner layer and an outer skin layer. The passivation inner layer is tightly bonded to the conductor layer molecules, while the outer skin layer is a continuous tubular seamless covering. Compared to existing single anti-corrosion layers, this provides double protection, eliminating localized corrosion caused by gaps between layers.

[0012] 2. The reinforcing layer uses a continuous spiral wrapping of aluminum-plastic composite tape, eliminating the defect of existing grounding wires without a reinforcing anti-corrosion layer. It forms an additional anti-corrosion barrier in highly corrosive environments, preventing corrosive media from seeping in through gaps. The wear-resistant layer is made of a material with uniform raised texture on the outer periphery. It achieves seamless bonding with the reinforcing layer through continuous extrusion, and the raised texture reduces the direct friction area with soil particles and stones. Its wear resistance exceeds that of existing ordinary plastic protective layers. The physical protective layer is made of modified high-density polyethylene with 3%-5% ultraviolet absorber, which makes up for the defect of ordinary polyethylene used in existing grounding wires being susceptible to ultraviolet aging and embrittlement. Even if the grounding wire is partially laid close to the ground or in exposed areas, it can still maintain structural integrity for a long time, greatly extending the overall service life of the grounding wire and adapting to the harsh environment of long-term outdoor underground laying of railways.

[0013] The present invention will be explained in detail below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0014] Figure 1 This is a top view of the structure of this utility model; Figure 2 This is a partial cross-sectional structural diagram of the present invention.

[0015] Numbering on the map: 1. Conductor layer; 2. Corrosion-resistant transition layer; 3. Reinforcing layer; 4. Wear-resistant layer; 5. Physical protective layer. Detailed Implementation

[0016] 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.

[0017] 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.

[0018] Please refer to the appendix carefully. Figure 1-2 A seamless through ground wire includes a conductor layer 1, an anti-corrosion transition layer 2, a reinforcing layer 3, a wear-resistant layer 4, and a physical protection layer 5. The anti-corrosion transition layer 2, the reinforcing layer 3, the wear-resistant layer 4, and the physical protection layer 5 are coaxially arranged from the inside to the outside and are wrapped around the outer periphery of the conductor layer 1 in a continuous tubular structure. The whole extends along the railway to form a seamless through structure.

[0019] In this embodiment, as Figure 1 and Figure 2 As shown, conductor layer 1 is formed by spirally twisting a trapezoidal cross-section copper wire as the center and several trapezoidal cross-section copper wires distributed radially outward around the center. The copper wires of adjacent layers are staggered and tightly attached in the radial direction to form a seamless twisted structure. Each copper wire is coated with an anti-oxidation protective coating.

[0020] With the above structure, conductor layer 1 is made of ≥99.95% pure copper. It is spirally twisted with a single trapezoidal cross-section copper wire as the center and radially distributed copper wires on the outer layer. Combined with the seamless structure of adjacent layers of copper wires radially interlaced and tightly attached, it can increase the conductor filling rate by reducing the gap between strands, increase the conductive area to reduce impedance, and meet the high conductivity requirements. The anti-oxidation protective coating on the outside of each copper wire can effectively isolate corrosive media such as oxygen and electrolytes in the soil, avoid oxidation and corrosion of the copper wire, and extend the service life of conductor layer 1.

[0021] In this embodiment, as Figure 1 and Figure 2 As shown, the anti-corrosion transition layer 2 includes a passivation inner layer and an outer skin layer. The passivation inner layer is a dense film structure covering the outer peripheral surface of the conductor layer 1, and the outer skin layer is a continuous tubular structure that tightly covers the outer peripheral surface of the passivation inner layer.

[0022] Through the above structure, the anti-corrosion transition layer 2 adopts a double-layer structure. The dense film-like passivation inner layer can directly adhere tightly to the outer surface of the conductor layer 1 to form intermolecular bonds. With the characteristics of copper oxide material, it effectively isolates the conductor layer 1 from direct contact with the outside air and soil electrolyte, avoiding copper oxidation and corrosion and ensuring high conductivity. High-density polyethylene is used as the outer skin material. The continuous tubular structure can further block the penetration of water and acid and alkali media in the soil into the inner layer, and can also resist the complex underground corrosion environment by relying on its own corrosion-resistant material, forming a double anti-corrosion barrier.

[0023] In this embodiment, as Figure 1 and Figure 2 As shown, the reinforcing layer 3 is an aluminum-plastic composite strip structure that is wrapped around the outer surface of the anti-corrosion transition layer 2 in a continuous spiral wrapping form.

[0024] Through the above structure, the aluminum-plastic composite belt uses an aluminum layer and a plastic layer. The aluminum layer can effectively isolate the strong corrosive media in the soil in the strong corrosion scenario along the railway, while the plastic layer can prevent the aluminum layer from oxidizing in direct contact with the soil. The two layers work together to form an additional anti-corrosion barrier, supplementing the protective ability of the anti-corrosion transition layer 2, and solving the problem that traditional single anti-corrosion layers are difficult to resist strong corrosion. Its continuous spiral wrapping shape can ensure that the aluminum-plastic composite belt is tightly wrapped around the outer periphery of the anti-corrosion transition layer 2, which can eliminate wrapping gaps and prevent corrosive media from seeping in from the gaps.

[0025] In this embodiment, as Figure 1 and Figure 2 As shown, the wear-resistant layer 4 is fixedly connected to the outer surface of the reinforcing layer 3 by continuous extrusion, and multiple raised texture structures are evenly distributed on the outer peripheral surface of the wear-resistant layer 4.

[0026] Through the above structure, the wear-resistant layer 4 is fixedly connected to the outer surface of the reinforcing layer 3 through a continuous extrusion process, which can achieve a seamless and tight fit, effectively preventing water and electrolytes in the soil from seeping into the gaps between the layers. On the other hand, the raised texture structure evenly distributed on the outer periphery can reduce the direct friction area with soil particles and stones during laying and use, improve wear resistance, further protect the inner core protective structure, and extend the overall service life of the grounding wire.

[0027] In this embodiment, as Figure 1 and Figure 2 As shown, the physical protective layer 5 is coated on the outer periphery of the wear-resistant layer 4 by a continuous extrusion process, and its outer periphery has a continuous smooth shape.

[0028] With the above structure, the physical protective layer 5 adopts a modified high-density polyethylene structure with added ultraviolet absorbers. Even when the grounding wire is laid close to the ground or in areas with partial exposure, it can block the aging and damage of ultraviolet rays to the material, avoid the embrittlement and cracking of traditional polyethylene due to long-term exposure to ultraviolet rays, and extend the service life of the protective layer.

[0029] The specific operating procedure of this utility model is as follows: It should be noted that this operating procedure focuses on the production and forming logic of the core layered structure of the seamless through grounding wire. The illustration only shows the main layered structure of the grounding wire and does not involve the end part connected to the grounding facilities along the railway line. In actual use, the seamless through grounding wire can be matched with the corresponding grounding terminal or connection joint to complete the electrical connection according to the interface type of the railway grade (ordinary railway / high-speed railway) and the laying environment (ordinary soil / highly corrosive soil). For example, a copper grounding terminal is installed every 100m. The terminal is welded to the conductor layer 1, and the weld is covered with anti-corrosion sealant. The following will describe in detail the production operation and functional manifestation of conductor layer 1, anti-corrosion transition layer 2, reinforcing layer 3, wear-resistant layer 4, and physical protection layer 5 in combination with specific application scenarios and the material and process characteristics of each layer.

[0030] Conductor layer 1, as the core conductive carrier of the seamless ground wire, is made of electrolytic copper with a purity of ≥99.95%. It is drawn into a trapezoidal cross-section copper wire by a wire drawing machine. The cross-sectional size is determined according to the cross-section of the target conductor. Then, a nano-level anti-oxidation protective coating is uniformly coated on the outer periphery of a single trapezoidal copper wire using a roller coating process. The coating material is a chromate composite agent with a thickness of 0.5-1μm. After coating, it is dried with hot air at 80-100℃.

[0031] The pre-treated trapezoidal copper wire is placed in a wire bundling machine and continuously spirally twisted around one strand as the center and the outer layers are wrapped around it. Then, the outer copper wires are added in sequence according to the designed number of layers. The copper wires of each layer are arranged at equal angles along the concentric circumference of the central core. At the same time, the twisting pitch is controlled to be 12-16 times the outer diameter of conductor layer 1 to ensure that the copper wires of adjacent layers are staggered in the radial direction and the trapezoidal inclined sides are tightly interlocked to form a seamless twisted structure.

[0032] The formed conductor layer 1 is placed into a passivation treatment tank. A chromate passivation solution with a concentration of 10%-12% is injected into the tank. The temperature in the tank is controlled at 45-50℃, and the immersion time is 4-6 minutes. During this time, the passivation solution is kept to flow evenly by a stirring device to ensure that all copper wire surfaces on the outer periphery of the conductor layer 1 can fully contact the passivation solution and undergo a chemical reaction to form a dense oxide film. After immersion, the conductor layer 1 is taken out of the passivation tank and sent to a hot air drying oven to finally form a passivated inner layer that is bonded to the molecular bonds on the outer periphery of the conductor layer 1.

[0033] The conductor layer 1 with the passivated inner layer is drawn to the extruder. High-density polyethylene is selected as the outer skin material. The molten high-density polyethylene is continuously extruded through the mold to cover the outer periphery of the passivated inner layer, forming a continuous tubular outer skin layer with a thickness of 2-2.5 mm. After extrusion, it immediately enters the warm water segmented cooling tank for cooling and shaping, forming a complete anti-corrosion transition layer 2.

[0034] An aluminum-plastic composite strip with a thickness of 0.1mm aluminum layer and a thickness of 0.07mm plastic layer is selected and installed on the unwinding frame of the wrapping machine. The semi-finished ground wire with anti-corrosion transition layer 2 is pulled to the wrapping machine. The wrapping machine is started so that the aluminum-plastic composite strip is continuously spirally wrapped around the outer periphery of the anti-corrosion transition layer 2 with the aluminum layer facing outward and the plastic layer facing inward.

[0035] Modified polypropylene granules are added to a twin-screw extruder with 22%-25% by weight of glass fiber with a length of 3-5mm. The mixture is melt-blended at 180-200℃ to produce a wear-resistant composite material. The semi-finished ground wire with reinforcement layer 3 is fed into an extruder. The wear-resistant composite material is added to the hopper, the extruder temperature is set, and the molten wear-resistant composite material is continuously extruded through a die with raised texture to coat the outer periphery of reinforcement layer 3, forming a wear-resistant layer with a thickness of 1.5-2mm. After extrusion, the material is rapidly cooled and shaped in a cold water bath. The raised texture can reduce the direct friction area with soil and stones during installation, thereby improving wear resistance.

[0036] Modified high-density polyethylene is selected according to the laying environment, and 3%-5% ultraviolet absorber is added. The semi-finished ground wire with wear-resistant layer 4 is fed into the extruder, the extrusion temperature is set, and it is continuously extruded through a smooth tubular die to form a tubular structure with a smooth outer circumference.

[0037] 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 seamless, continuous ground wire, characterized in that: It includes a conductor layer (1), an anti-corrosion transition layer (2), a reinforcing layer (3), a wear-resistant layer (4), and a physical protective layer (5). The anti-corrosion transition layer (2), the reinforcing layer (3), the wear-resistant layer (4), and the physical protective layer (5) are coaxially arranged from the inside to the outside and wrapped around the outer periphery of the conductor layer (1) in a continuous tubular structure. The whole extends along the railway to form a seamless through structure.

2. The seamless grounding wire according to claim 1, characterized in that: The conductor layer (1) is formed by spirally twisting a trapezoidal cross-section copper wire as the center and several trapezoidal cross-section copper wires distributed radially outward around the center. The copper wires of adjacent layers are staggered and tightly attached in the radial direction to form a seamless twisted structure. Each copper wire is coated with an anti-oxidation protective coating.

3. The seamless grounding wire according to claim 1, characterized in that: The anti-corrosion transition layer (2) includes a passivation inner layer and an outer skin layer. The passivation inner layer is a dense film structure covering the outer peripheral surface of the conductor layer (1), and the outer skin layer is a continuous tubular structure that tightly covers the outer peripheral surface of the passivation inner layer.

4. A seamless grounding wire according to claim 1, characterized in that: The reinforcing layer (3) is an aluminum-plastic composite strip structure, which is wrapped around the outer periphery of the anti-corrosion transition layer (2) in a continuous spiral wrapping form.

5. A seamless grounding wire according to claim 1, characterized in that: The wear-resistant layer (4) is fixedly connected to the outer surface of the reinforcing layer (3) by continuous extrusion, and the outer peripheral surface of the wear-resistant layer (4) has a number of raised texture structures evenly distributed.

6. A seamless grounding wire according to claim 1, characterized in that: The physical protective layer (5) is coated on the outer periphery of the wear-resistant layer (4) by a continuous extrusion process, and its outer periphery has a continuous smooth shape.

Images