CN121237493A

CN121237493A - A segmented functionalized rigid-flex cable and its manufacturing method

Info

Publication number: CN121237493A
Application number: CN202511184360.6A
Authority: CN
Inventors: 闻学; 陈龙; 娄永超; 吉庆隆; 刘甜; 宋明明; 谢静; 王毅
Original assignee: Tbea Deyang Cable Stock Co ltd
Current assignee: Tbea Deyang Cable Stock Co ltd
Priority date: 2025-08-22
Filing date: 2025-08-22
Publication date: 2025-12-30

Abstract

This invention provides a segmented, functionally-designed flexible-rigid hybrid cable and its manufacturing method, relating to the field of cable design technology. The cable comprises, from the inside out: a conductor, an insulation layer, and a sheath; between the insulation layer and the sheath, within a defined length range, an inner liner and an armor layer are provided from the inside out; the end of the armor layer has a conical buffer section with its larger end facing the armor layer; the buffer section is covered by a fixing layer. This invention breaks through the traditional single-structure mode of "all-flexible" or "all-rigid" cables, achieving customized segmentation of flexible and rigid sections on a single cable. The cable uses a conductor with high flexibility and low hardness, making it easy to bend and convenient for laying and installation; the armor layer is added to areas susceptible to mechanical damage, making the cable less prone to damage.

Description

Soft and hard combined cable based on segmented functionalization and manufacturing method thereof

Technical Field

The invention relates to the technical field of cable design, in particular to a soft and hard combined cable based on segmented functionalization and a manufacturing method thereof.

Background

In the cable laying process, the whole cable is needed, and the two cables are prevented from being connected by a connector as much as possible. Existing cables include a variety of structures such as flexible cables and armored cables. Flexible cables are highly flexible and easy to install in complex environments, but are difficult to meet the requirements of mechanical damage resistance, and the flexible cables have the disadvantages of complex production process and easy breakage of monofilaments under impact due to the adoption of flexible conductors. Although the armored hard-structure cable can protect the cable, the cable has poor flexibility, large laying radius and difficult installation in a complex environment.

In the current installation and use process of the cable, when one cable needs to be laid in a changeable laying environment, the cable is required to meet contradictory requirements of flexible laying requirements (such as narrow spaces at corners) and mechanical damage resistance (such as aisles), and at the moment, the flexible cable or the armored cable cannot meet the requirements.

Disclosure of Invention

Aiming at the defects of the prior art, the invention aims to provide a soft and hard combined cable based on sectional functionalization and a manufacturing method thereof, wherein armor is arranged on the outer side of a continuous conductor within a set range to form a hard section, the position without armor is a soft section, a transition soft cushion is arranged between the hard section and the soft section, and the outermost side is coated with a sheath, so that one cable meets the respective requirements of different positions in a laying environment.

In order to achieve the above object, the present invention is realized by the following technical scheme:

A soft and hard combined cable based on sectional functionalization is characterized in that a conductor, an insulating layer and a sheath are arranged from inside to outside, a gap is reserved between the insulating layer and the sheath, an inner liner layer and an armor layer are arranged from inside to outside within a set length range of the gap along the length direction of the cable, conical buffer parts are arranged at the end parts of the inner liner layer and the armor layer, the large end of the conical buffer parts face the inner liner layer and the armor layer, and a fixing layer is coated outside the buffer parts.

In a second aspect, the preparation method of the soft and hard combined cable based on the segmented functionalization includes the following steps:

S1, coating an insulating layer on the outer side of a conductor, and coating an inner liner layer and an armor layer within a set length range;

s2, wrapping a buffer part at the end part of the armor layer, and wrapping a fixed layer outside the buffer part to obtain a non-sheath cable;

and S3, preparing the sheath on the outer side of the unshielded cable in an extrusion molding mode, and obtaining the soft and hard combined cable based on segmented functionalization.

The beneficial effects of the invention are as follows:

The invention breaks through the single structure mode of the traditional cable of 'full soft' or 'full hard', and realizes the customization of soft and hard segment partition on a single cable. The cable is made of conductors with high flexibility and low hardness, is easy to bend and convenient to lay and install, and the armor layer is additionally arranged in the area which is easy to be damaged mechanically, so that the cable is not easy to be damaged. Therefore, the cable is easy to bend at the place where the armor layer is not added, has strong damage resistance at the place where the armor layer is added, is custom-designed according to the actual installation environment, and meets the use requirements of spanning multiple installation scenes by one cable. And only the area needing to be protected is additionally provided with the armor layer, so that the material cost can be obviously reduced, and the weight of a product can be reduced.

Drawings

The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention.

Fig. 1 is a schematic structural diagram of a soft and hard combined cable based on segment functionalization in embodiment 1, wherein 1, a conductor, 2, an insulating layer, 3, an inner liner, 4, an armor layer, 5, a buffer part, 6, a fixing layer, 7 and an outer sheath.

FIG. 2 is a schematic view of the shape of the butyl self-adhesive tape of example 1, wherein (A) is a front view and (B) is a side view.

Detailed Description

It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the invention. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present invention. As used herein, the singular is also intended to include the plural unless the context clearly indicates otherwise, and furthermore, it is to be understood that the terms "comprises" and/or "comprising" when used in this specification are taken to specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof.

The invention provides a soft and hard combined cable based on segmented functionalization, which comprises a conductor, an insulating layer and a sheath from inside to outside, wherein a gap is formed between the insulating layer and the sheath, an inner liner layer and an armor layer are arranged in a set length range of the gap along the length direction of the cable from inside to outside, cone-shaped buffer parts are arranged at the end parts of the inner liner layer and the armor layer, the large ends of the cone-shaped buffer parts face the inner liner layer and the armor layer, and a fixing layer is coated outside the buffer parts.

Through the structure, the cable is divided into the soft section and the hard section, wherein the soft section is not provided with the armor layer, the laying radius is small, the cable is suitable for a narrow space (such as a folded corner) needing bending, the hard section is provided with the armor layer, the protection effect is good, the laying radius is large, and the cable is suitable for spaces such as a road. The soft section and the hard section adopt the same continuous conductor, and the outer side is coated with a continuous sheath, so that the conductive and safety requirements can be met.

The conductor is exemplified by a5 th soft copper conductor or a specially processed 2 nd stranded copper conductor with low rebound property, the conductor property accords with the specification of the prior standard GB/T3956, is easy to bend, and accords with bending requirements and conductive performance requirements in a laying scene.

When the cable is of a multi-core structure, a plurality of cable cores coated with insulating layers are stranded into a cable, and tape, an inner liner and an armor layer are sequentially arranged in gaps between the cable cores and the sheath from inside to outside, wherein the tape is used for fixing the relative positions of the cable cores.

Optionally, an electromagnetic shielding layer is arranged between the inner liner layer and the insulating layer, so that the related technical requirements of electromagnetic shielding are met.

Optionally, the material of the buffer part comprises one or more of butyl rubber, foamed polyethylene and thermoplastic polyurethane, the material has good elasticity, good compatibility with materials such as cable insulation and jackets, and the temperature resistance level meets the operation requirement of the cable, and the material of the buffer part is connected with the internal structure in an adhesive mode, so that the processing is convenient.

Optionally, the cone angle of the buffer part is 15-20 degrees, the buffer layer fills the height difference between the hard section and the soft section and the right-angle gap formed, an elastic transition region with gradually changed modulus is formed, the abrupt change of structural rigidity is greatly reduced, and meanwhile, cracking points and internal pores caused by suspension or incomplete filling during sheath extrusion molding are eliminated.

Optionally, the fixed layer cladding buffer to extend the surface of setting length at armor and insulating layer that buffer both ends were exposed respectively, can integrate the parcel with armor tip, buffer and insulating inner liner into a whole, reinforcing transition zone's structural rigidity and stability provide a level and smooth, firm basal plane for the extrusion of follow-up sheath.

One or more specific embodiments of the present invention provide a method for preparing the soft and hard combined cable based on segmented functionalization, which comprises the following steps:

In the above process, processing continuous conductor into including soft section and hard section's cable can satisfy changeable laying environment requirement, sets up buffer unit and cladding fixed layer outside the buffer unit between hard section and soft section, can prevent effectively that the armor from separating and improve subsequent sheath extrusion molding quality.

Optionally, in S1, the conductor is annealed after being twisted, and illustratively, a2 nd copper conductor meeting the requirements of GB/T3956-2008 is adopted, and is heated to 350-450 ℃ in an inert atmosphere for annealing after being twisted, so that the flexibility is improved (namely, the 2 nd stranded copper conductor with low rebound property) or illustratively, a 5 th copper conductor meeting the requirements of GB/T3956-2008 is adopted.

Optionally, in S1, the inner liner is prepared by extrusion or wrapping, and is used for isolating the armor layer from the internal structure, preventing the armor layer from damaging the internal structure in the preparation process, the armor layer is made of an armor steel tape, the thickness range of the armor layer meets the corresponding standard specification of the product, and is used for protecting the conductor inside, the inner liner is extruded or wrapped outside the insulating layer for a single-core cable, the multiple-core cable is twisted into a cable after the insulating layer is prepared, and the inner liner is prepared outside in a wrapping manner after the insulating layer is fixed by a wrapping tape.

Optionally, in S2, the end of the armor layer is coated by the large end of the wedge-shaped elastic material, the insulating layer not covered by the armor layer is coated by the small end of the wedge-shaped elastic material, so that the plurality of wedge-shaped elastic materials form a cone-shaped buffer part around the conductor, and the coated armor layer end can effectively absorb and buffer the shearing stress and the stripping stress concentrated at the armor endpoint when the cable is bent, prevent the stresses from directly acting on the sheath to cause cracking, and prevent the inner liner layer from being separated from the armor layer due to the stress.

Optionally, in S2, the coating range of the fixing layer in the cable length direction is greater than the buffer portion, and two ends of the coating range respectively exceed 20-30 cm of the buffer portion, for the armor layer, a radial constraint force can be applied to the terminal end of the armor steel belt to directly prevent the end of the steel belt from tilting or opening due to elasticity or external force, so that the end of the steel belt is firmly pressed on the inner lining layer and the buffer belt, for the cone-shaped buffer portion, the buffer portion can be tightly bound at a preset position, the soft buffer belt surface is protected from being scratched or polluted before the sheath extrusion, and displacement, deformation or falling of the buffer belt in the subsequent sheath extrusion process can be prevented.

The invention is further illustrated below with reference to examples.

Example 1

A soft and hard combined cable based on segmented functionalization is provided with a conductor 1, an insulating layer 2 and a sheath 7 from inside to outside, a gap exists between the insulating layer 2 and the sheath 7, an inner liner 3 and an armor layer 4 are arranged in the set length range of the gap along the length direction of the cable from inside to outside, conical buffer parts 5 are arranged at the ends of the inner liner 3 and the armor layer 4, the large ends of the conical buffer parts 5 face the inner liner 3 and the armor layer 4, the inner liner 3 and the armor layer 4 are coated outside the buffer parts in the set length range of the fixed layers, the conical buffer parts 5 are arranged at the ends of the armor layer 4 face the armor layer from inside to outside, and the fixed layers 6 are coated outside the buffer parts 5.

The conductor 1 is a stranded conductor made of copper, is a low-rebound conductor and is easy to bend.

The inner liner 3 is made of high polymer materials with good wear resistance and is used for isolating the armor layer 4 from the insulating layer 2 and preventing the inner structure from being damaged in the preparation process of the armor layer.

The material of the buffer part 5 is butyl rubber, and a butyl rubber self-adhesive tape is specifically adopted, namely, the connection mode of the buffer part and the internal structure is bonding.

The taper angle of the buffer 5 is 15 deg. to make the hard and soft sections of the cable smoothly transition.

The fixed layer 6 is made of a non-woven fabric polyester fiber tape, and is coated with a buffer part 5, and an armor layer 4 and an insulating layer 2 which are 20cm long beyond the two ends of the buffer part 5.

The preparation method of the soft and hard combined cable based on the segmented functionalization of the embodiment comprises the following steps:

s0, designing the whole structure of the cable according to the condition of the actual field construction environment requirement, and designing an armor layer in the length range of the cable to be protected, wherein the armor layer is not designed at other positions;

S1, adopting a 2 nd copper conductor meeting the specification of GB/T3956-2008, heating to 400 ℃ in an inert atmosphere for annealing after twisting to enable the copper conductor to meet the flexibility requirement, circumferentially spirally winding an insulating layer 2 or extruding the insulating layer 2 outside the conductor, preparing an inner liner 3 by an extrusion molding method within a set length range, and spirally winding an armor steel belt to form an armor layer 4;

S2, processing the butyl rubber self-adhesive tape into wedge-shaped strips shown in FIG. 2, connecting the root parts of the wedge-shaped strips as shown in (A) in FIG. 2, and ensuring that the wedge-shaped strips are convenient to operate, wrapping the armor layer at the notch position at the upper left corner in (B) in FIG. 2, enabling the outer surface of the buffer part 5 to be in smooth transition, immediately constructing a section at the terminal point of the armor layer 4 after the armor steel tape is wrapped and fixed with the terminal point, tightly wrapping the thickest end of the wedge-shaped butyl rubber self-adhesive tape at the end of the armor layer 4 without folds, wrapping the set range of the armor layer 4, ensuring that the wedge-shaped strips completely cover the sharp edge and the terminal point of the armor steel tape, flattening the wedge-shaped strips, attaching the wedge-shaped strips onto the insulating layer along the length direction of the cable, ensuring that the wedge-shaped strips are smoothly transited to the insulating layer of the soft section, utilizing self-adhesive bonding of the wedge-shaped strips to obtain a cone-shaped buffer part 5, spirally wrapping a fixed layer 6 outside the buffer part 5 along the circumferential direction of the cable, enabling the fixed layer 6 to completely wrap the buffer part 5, and the armor layer 4 and the insulating layer 2 within 20cm of the exposed at the two ends of the buffer part 5, and obtaining a sheathing-free cable;

and S3, preparing the sheath 7 on the outer side of the unshielded cable in an extrusion molding mode, and obtaining the soft and hard combined cable based on sectional functionalization.

Example 2

A soft and hard combined cable based on segmented functionalization is different from embodiment 1 in that the soft and hard combined cable is a multi-core cable, a 5 th soft copper conductor conforming to GB/T3956-2008 is adopted as a conductor, and a buffer part is made of foamed polyethylene.

In this embodiment, a plurality of insulated cable cores are stranded into a cable, and then the relative positions of a plurality of cable cores are fixed with the band, the band outside is in order to wrap up the mode preparation inner liner, and the inner liner outside sets gradually armor and sheath.

Example 3

A soft and hard combined cable based on sectional functionalization is different from embodiment 1 in that an electromagnetic shielding layer is arranged between an insulating layer and an inner liner layer to play a role of electromagnetic shielding.

The above is only a preferred embodiment of the present application, and is not intended to limit the present application, but various modifications and variations can be made to the present application by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the protection scope of the present application.

Claims

1. A segmented, functionally-based rigid-flex cable, characterized in that, from the inside out, it comprises: a conductor, an insulation layer, and a sheath; a gap exists between the insulation layer and the sheath; within a predetermined length range along the cable length direction of the gap, an inner liner and an armor layer are provided from the inside out; a conical buffer portion is provided at the end of the inner liner and the armor layer, the larger end of the conical portion facing the inner liner and the armor layer; a fixing layer is wrapped around the outside of the buffer portion.

2. The segmented functionalized rigid-flex cable as described in claim 1, wherein the conductor is a stranded copper conductor and the armor layer is made of armored steel tape.

3. The flexible and rigid combined cable based on segmented functionalization as described in claim 1, characterized in that an electromagnetic shielding layer is provided between the inner liner layer and the insulation layer;

Alternatively, the material of the buffer portion may include one or more of butyl rubber, foamed polyethylene, and thermoplastic polyurethane;

Alternatively, the cone angle of the buffer section is 15~20°.

4. The flexible and rigid combined cable based on segmented functionality as described in claim 1, characterized in that the flexible and rigid combined cable has a multi-core structure, in which multiple cable cores covered with insulation layers are twisted together, and in the gap between the cable core and the sheath, a wrapping tape, the inner lining layer and the armor layer are arranged sequentially from the inside to the outside.

5. The segmented functionalized rigid-flex cable as claimed in claim 1, characterized in that the fixing layer covers the buffer portion, and extends by a predetermined length on the surfaces of the armor layer and the insulation layer exposed at both ends of the buffer portion.

6. A method for manufacturing a segmented, functionally-based rigid-flex cable as described in any one of claims 1-5, characterized in that it comprises the following steps:

S1. Cover the outside of the conductor with an insulating layer, and cover the inner liner and armor layer within a set length range;

S2. Cover the end of the armor layer with a buffer portion, and cover the outside of the buffer portion with a fixing layer to obtain an unsheathed cable;

S3. An extrusion process is used to prepare a sheath on the outside of the unsheathed cable to obtain a rigid-flexible cable based on segmented functionality.

7. The method for preparing a segmented functionalized rigid-flex cable as described in claim 6, characterized in that, in S1, the conductor undergoes annealing treatment after stranding.

8. The method for preparing a segmented functionalized rigid-flex cable as described in claim 6, wherein in S1, the inner liner is prepared by extrusion or wrapping.

9. The method for preparing a segmented functionalized rigid-flexible cable as claimed in claim 6, characterized in that, in S2, a wedge-shaped elastic material is used to surround the insulation layer to form a conical buffer portion, the large end of the conical portion is covered and bonded to the end of the armor layer, and the small end is bonded to the insulation layer that is not covered by the armor layer.

10. The method for preparing a segmented functionalized rigid-flexible cable as claimed in claim 6, characterized in that, in S2, the coverage area of the fixing layer in the cable length direction is larger than that of the buffer portion, and both ends of the coverage area extend 20-30 cm beyond the buffer portion.