CN118280650A - High-power constant-temperature cable and preparation method thereof - Google Patents
High-power constant-temperature cable and preparation method thereof Download PDFInfo
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- CN118280650A CN118280650A CN202410709334.XA CN202410709334A CN118280650A CN 118280650 A CN118280650 A CN 118280650A CN 202410709334 A CN202410709334 A CN 202410709334A CN 118280650 A CN118280650 A CN 118280650A
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- 238000002360 preparation method Methods 0.000 title abstract description 13
- 238000001816 cooling Methods 0.000 claims abstract description 126
- 229920001296 polysiloxane Polymers 0.000 claims abstract description 90
- 239000004519 grease Substances 0.000 claims abstract description 77
- 238000002955 isolation Methods 0.000 claims abstract description 25
- 238000011049 filling Methods 0.000 claims abstract description 17
- 239000002131 composite material Substances 0.000 claims abstract description 12
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 97
- 239000000741 silica gel Substances 0.000 claims description 97
- 229910002027 silica gel Inorganic materials 0.000 claims description 97
- 238000000034 method Methods 0.000 claims description 53
- 239000004020 conductor Substances 0.000 claims description 45
- 238000001125 extrusion Methods 0.000 claims description 44
- 239000000463 material Substances 0.000 claims description 36
- 229910001220 stainless steel Inorganic materials 0.000 claims description 25
- 239000010935 stainless steel Substances 0.000 claims description 25
- 239000000853 adhesive Substances 0.000 claims description 21
- 229920000840 ethylene tetrafluoroethylene copolymer Polymers 0.000 claims description 21
- 229920001721 polyimide Polymers 0.000 claims description 21
- 229920002725 thermoplastic elastomer Polymers 0.000 claims description 21
- 235000011837 pasties Nutrition 0.000 claims description 15
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 14
- 238000010438 heat treatment Methods 0.000 claims description 14
- 238000000465 moulding Methods 0.000 claims description 14
- 229920002379 silicone rubber Polymers 0.000 claims description 14
- 239000004945 silicone rubber Substances 0.000 claims description 9
- 229910000831 Steel Inorganic materials 0.000 claims description 7
- 229910052802 copper Inorganic materials 0.000 claims description 7
- 239000010949 copper Substances 0.000 claims description 7
- 238000003618 dip coating Methods 0.000 claims description 7
- 239000010959 steel Substances 0.000 claims description 7
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 230000017525 heat dissipation Effects 0.000 abstract description 11
- 230000000694 effects Effects 0.000 abstract description 10
- 238000013461 design Methods 0.000 description 26
- 238000005452 bending Methods 0.000 description 12
- 238000005516 engineering process Methods 0.000 description 8
- 239000002826 coolant Substances 0.000 description 7
- 230000002349 favourable effect Effects 0.000 description 5
- 230000009286 beneficial effect Effects 0.000 description 4
- 238000009413 insulation Methods 0.000 description 4
- 238000005253 cladding Methods 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000005461 lubrication Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 238000013459 approach Methods 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 239000000110 cooling liquid Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
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Abstract
The invention relates to the technical field of cables, and particularly discloses a high-power constant-temperature cable and a preparation method thereof. The high-power constant-temperature cable comprises a cable core with a composite structure, and an isolation layer and a sheath layer which are coated outside the cable core; the cable core is formed by twisting a plurality of power wire cores and at least one cooling pipe with a hollow structure, heat conduction silicone grease is filled in the twisting gaps in a full filling structure, and the heat conduction silicone grease respectively coats the cooling pipe and each power wire core on the cross section, so that the outer wall of the cooling pipe is respectively communicated with the outer wall of each power wire core. The invention establishes a reliable heat conduction path between the outer wall of the power wire core and the outer wall of the cooling pipe, so that the heat dissipation of the power wire core is basically not influenced by the arrangement position of the power wire core and the cooling pipe and the quantity of contact areas, the heat exchange efficiency between each power wire core of the twisted structure cable core and the cooling pipe is effectively improved, the heat dissipation effect is excellent, and the inside of the cable core of the high-power cable is basically kept in a relatively balanced constant temperature state.
Description
Technical Field
The invention relates to the technical field of cables, in particular to a high-power constant-temperature cable and a preparation method thereof.
Background
The rechargeable automobile is taken as a new energy automobile, has an energy saving advantage which is incomparable with the traditional fuel automobile, and is a trend of automobile development in the future. In recent years, with the continuous breakthrough of the power battery technology of the electric automobile, new energy charging automobiles are rapidly developed, and the market popularity is higher.
For a long time, a major technical bottleneck restricting the popularization of new energy charging automobiles is mainly that the charging time is too long, and the convenience and experience of the users for using the automobiles are directly reduced. In order to solve the technical problem that the charging time of a charging car is too long, the rapid charging technology becomes a direction of attention and important development in the industry. The quick charging is realized by two technical approaches of improving the charging voltage and increasing the charging current, and the charging voltage is difficult to improve due to the working voltage of the whole vehicle, so that the charging current is increased to be a technical path which is easier to realize.
The charging current is increased by using a high-power cable with larger current carrying capacity, and the high-power cable generates heat due to the high-power current carrying of the conductor, so that a high-temperature environment is easily formed in the cable core. In order to ensure the stable and long-acting service of the high-power cable and ensure the safety of electric equipment, the high-power cable has good heat dissipation characteristic so as to avoid the occurrence of wire burning safety accidents caused by overheating of conductors under a high-power current-carrying working condition.
The traditional heat dissipation technical problem of solving high power cable is enough big with the cross section structure size design of cable, makes the sheath of cable have enough big radiating surface, and the heat of conductor pierces through insulating sheath and dispels the heat to outside environment, realizes heat exchange. The technical means has the technical problems of low heat exchange rate, heavy cable structure, poor bending performance and the like, is difficult to adapt to the power transmission working condition environment including a charging automobile, is time-consuming and labor-consuming in dragging operation in the working condition environment, is inconvenient to use, and also has the technical problems of more manufacturing materials and higher cost.
In recent years, a technology of heat exchanging a conductor by introducing a cooling medium by providing a cooling tube inside a cable core in a composite manner has been disclosed in the prior art. The composite structure of the cooling tube inside the cable core is common in three structural forms. The first is a technology of arranging cooling pipes around the power core, and surrounding the power core with cooling pipes, for example, the technology disclosed in chinese patent literature is named "a liquid-cooled cable for wind power generation", publication No. CN216980151U, publication No. 2022, month 07, 15, named "flexible cable for new energy automobile", publication No. CN107039117a, publication No. 2017, month 08, 11, and the technology named "a liquid-cooled electric car high-voltage cable", publication No. CN117766221a, publication No. 2024, month 03, 26, etc. The second is a technique of arranging a power core or a conductor around a cooling pipe around the cooling pipe, and surrounding the cooling pipe with the power core or the conductor, for example, a technique of "hollow self-cooling cable" disclosed in chinese patent literature, a publication No. CN101546626a, a publication No. 2009, 09 months and 30 days, and a technique of "cooled charging cable", a publication No. CN116057646a, a publication No. 2023, 05 months and 02 days, etc. The third is to twist a plurality of power cores and a plurality of cooling pipes together, so that each cooling pipe is dispersed in the twisted structure of the power cores, for example, the technology disclosed in chinese patent literature is named "one kind of liquid cooling cable", publication No. CN116705413a, publication No. 2023, 09 month 05, and the technology named "systematic heat conduction mechanism in one kind of liquid cooling cable", publication No. CN217035241U, publication No. 2022, month 07, month 22, etc. In comparison with the three structural forms of the composite structure of the cooling pipe in the cable core, in the same nominal section, the cable cross-section structural dimension of the first structural form is the largest, the cable cross-section structural dimension of the second structural form is the next largest, and the cable cross-section structural dimension of the third structural form is the smallest.
Therefore, the cable with the third structural form is beneficial to compact and high-softness molding, and is further beneficial to flexible arrangement in working condition environments. However, in the third structural form, since the cooling pipes are dispersedly twisted among the plurality of power cores, the arrangement positions of some power cores are far away from the cooling pipes in the cross section, which is more obvious especially in the case of a large number of power cores, and even the power cores adjacent to the cooling pipes, only a small part of the circumference of the cross section are in direct contact fit with the cooling pipes, so that under the obstruction of air and/or full-circle filler in the twisting gap and the influence of the structure of insufficient heat conduction contact fit, the heat conduction efficiency between the power cores and the cooling pipes is low, and the heat dissipation cooling effect inside the cable core is not ideal. That is, compared with the three structural forms of the composite structure of the cooling pipe in the cable core, the third structural form has the lowest heat conduction efficiency and the worst cooling effect.
In order to enable the high-power cable to be flexibly arranged in a working condition environment, compact and high-flexibility to be formed, the high-power cable with the cable core in the third structural form is required to be optimally designed so as to improve the heat conduction efficiency and the cooling effect.
Disclosure of Invention
The technical purpose of the invention is that: aiming at the particularity of the high-power cable and the defects of the prior art, the high-power constant-temperature cable with compact structure, good flexibility and excellent heat dissipation effect and the preparation method thereof are provided.
The technical aim of the invention is achieved by the following technical scheme that the high-power constant-temperature cable comprises a cable core with a composite structure, and an isolation layer and a sheath layer which are coated outside the cable core;
the cable core is formed by twisting a plurality of power wire cores and at least one cooling pipe with a hollow structure;
In the stranding structure of the cable core, heat conduction silicone grease is filled in the stranding gaps in a full filling structure, and the heat conduction silicone grease respectively coats the cooling pipe and each power wire core on the cross section, so that the outer wall of the cooling pipe is respectively communicated with the outer wall of each power wire core.
The technical measures aim at the particularity of the high-power cable, the twisted structure cable core with the cooling pipe is filled with the heat-conducting silicone grease with high heat conduction characteristics in the twisted gaps of the twisted structure cable core by the full filling structure, so that a reliable heat conduction path is established between the outer wall of the power cable core and the outer wall of the cooling pipe by the heat-conducting silicone grease, and heat emitted by the power cable core is reliably transferred to the cooling pipe through the heat-conducting silicone grease and is carried away by a cooling medium in the cooling pipe, thereby the heat dissipation of the power cable core is basically not influenced by the arrangement position far from or near to the cooling pipe and the quantity of contact areas, the heat exchange efficiency between each power cable core of the twisted structure cable core and the cooling pipe is effectively improved, the excellent heat dissipation effect is achieved, and the inside of the cable core of the high-power cable is basically kept in a relatively balanced constant temperature state. In addition, the cable core is twisted and formed by a plurality of power wire cores and the cooling pipes through the technical measures, so that the technical requirements of high power current carrying are met, the cross section structural dimension of the cable is formed in a miniaturized compact structure, the softness of the cable is improved, and the cable is convenient to flexibly arrange in a working condition environment.
As one of the preferred embodiments, the cable core has a plurality of cooling pipes which are distributed among the twisted structures of the plurality of power cores and are not adjacent to each other in cross section. The technical measure is favorable for increasing the heat exchange efficiency between the power wire core and the cooling pipe, and further improves the heat dissipation effect.
As one of the preferable technical schemes, the cooling tube is composed of a silica gel base tube with a hollow structure and an armor layer with a stainless steel band structure which is spirally wrapped on the periphery of the silica gel base tube along the axial direction of the silica gel base tube;
And the heat conduction silicone grease filled in the cable core passes through the spiral wrapping gap of the armor layer to wrap the outer wall of the silica gel base tube.
The cooling pipe forming structure of the technical measure does not influence the contact cladding of the heat conduction silicone grease on the silica gel base pipe on one hand, namely, the reliable establishment of the heat conduction path of the heat conduction silicone grease; the spiral armor layer of the stainless steel belt structure is used for forming extrusion-proof protection on the flexible silica gel base pipe, namely the spiral armor layer is used for effectively and directly bearing external impact force or cable bending force so as to basically isolate the flexible silica gel base pipe, thereby avoiding deformation of the flexible silica gel base pipe which is easy to deform and influence smooth flow of cooling medium due to the impact force or bending force, and ensuring that the cooling medium can stably and smoothly flow and exchange heat in the silica gel base pipe; the spiral armor structure of the three-aspect stainless steel belt is provided with the spiral wrapping gap, so that the bending performance of the cable is not hindered, namely, the softness of the cable is not damaged due to the existence of the armor layer on the cooling pipe.
Further, the silica gel base pipe is a silicon rubber material extrusion pipe molding structure with the Shore hardness of 70A-80A;
the inner diameter of the silica gel base pipe is 4.5 mm-6.0 mm;
The wall thickness of the silica gel base tube is 1.2 mm-1.5 mm;
the armor layer is a spiral wrapping structure formed by a 304 type stainless steel belt with the thickness of 0.4-0.5 mm, and the gap spacing of the spiral wrapping is 3-4 mm;
Under the concentric fit state of the armor and the silica gel base pipe, the annular fit clearance between the inner wall of the armor and the outer wall of the silica gel base pipe is less than or equal to 1.0mm.
The silica gel base pipe with the technical measures has good flexibility, and can not obstruct the bending flexibility of the cable; the sealing and isolating performance is good, and the cooling medium, such as cooling liquid, cannot be radially leaked out; the three aspects have good heat conduction characteristics, and are favorable for heat exchange fully.
On one hand, the armor layer of the technical measure has lateral pressure resistance up to 30kg and excellent compression resistance and bending resistance technical effect; the filling of the heat conduction silicone grease at the outer wall of the silica gel base tube is not hindered, and the reliable establishment of a heat conduction path of the heat conduction silicone grease is facilitated; the three aspects are that under the lubrication and isolation of the heat conduction silicone grease, the stainless steel tape armor layer is not easy to damage and influence the silica gel base pipe; the fourth aspect is under the lubrication isolation of heat conduction silicone grease and the spiral lapping influence of stainless steel strip, but armor and silica gel base pipe relative displacement slip in axial direction, and soft bending performance is excellent, is favorable to improving the softness performance of fashioned cable.
As one of the preferable technical schemes, the power wire core is composed of a plurality of conductors formed by twisting copper wire bundles with the diameters of 0.08-0.13 mm and an insulating layer formed by extruding and wrapping modified ethylene-tetrafluoroethylene copolymer outside the conductors;
the extrusion thickness of the insulating layer is 0.30 mm-0.40 mm.
The power wire core adopting the technical measures not only can meet the technical requirement of high-power current carrying, but also has good soft bending performance, and is beneficial to improving the soft performance of the formed cable.
As one of the preferable technical schemes, the isolation layer is a self-adhesive polyimide film with the thickness of 0.02-0.04 mm, and is in an overlapped wrapping structure outside the cable core;
The overlapping rate of the overlapping wrapping structure is more than or equal to 30 percent.
The isolation layer of the technical measure has good cladding tightness, particularly the overlapping cover part of the overlapped wrapping can form integrated sealing by self adhesion, which is favorable for reliably restraining and cladding the heat conduction silicone grease in the clad cable core, avoiding the loss of the heat conduction silicone grease in the cable molding process and further being favorable for guaranteeing the quality of the molded cable.
As one of the preferable technical schemes, the sheath layer is made of thermoplastic elastomer material with the Shore hardness of 70A-80A, and is an extrusion structure outside the isolation layer;
the extrusion thickness of the sheath layer is 1.2 mm-1.6 mm, and the extrusion concentricity is more than or equal to 90%.
The sheath layer of the technical measure has good flexibility, can not obstruct the bending softness of the cable, and is wear-resistant and weather-resistant.
The preparation method of the high-power constant-temperature cable comprises the following process steps:
step 1, respectively forming a power wire core and a cooling pipe;
Step 2, twisting the power wire cores and the cooling pipes with designed numbers together in a concentric arrangement structure by adopting a cabling machine, wherein the twisting pitch diameter ratio is 8-16 times;
In the twisting process of the power wire core and the cooling pipe, filling pasty heat-conducting silicone grease in twisting gaps in a dip-coating mode, and overlapping and wrapping a cable core with the heat-conducting silicone grease by adopting a self-adhesive polyimide film, wherein the overlapping and wrapping coverage rate of the self-adhesive polyimide film is more than or equal to 30%;
step 3, heating and plasticizing the thermoplastic elastomer material at 160-200 ℃ by adopting an extruder;
And (2) extruding the heated and plasticized thermoplastic elastomer material outside the cable core in the step (2) in a pipe extruding mode according to the designed size to form the sheath layer.
Further, the power wire core in the step 1 is formed according to the following process steps:
step I, twisting copper wires with designed quantity according to a concentric arrangement structure by adopting a wire twisting machine, wherein the twisting pitch diameter ratio is 8-14 times to form a twisted conductor;
Step II, heating and plasticizing the modified ethylene-tetrafluoroethylene copolymer at 265-300 ℃ by adopting an extruder;
And (3) extruding and molding the insulating layer outside the bundle conductor in the step I by a pipe extruding mode according to the designed size by using the heated and plasticized modified ethylene-tetrafluoroethylene copolymer.
Further, the cooling pipe in the step 1 is formed according to the following process steps:
①, extruding a silicone rubber material into a tube according to a designed size by adopting an extruder, wherein the temperature of a screw rod and a machine head part of the extruder is controlled within 40 ℃ in the process, and a blank of the silicone base tube is obtained;
②, vulcanizing the silica gel base pipe blank obtained by extrusion molding by using steam at 150-160 ℃ to obtain a silica gel base pipe;
and ③, adopting a steel belt spiral armoring machine to spirally cover the selected 304-type stainless steel belt on the surface of the silica gel base pipe in the step ② according to the designed size, and obtaining the cooling pipe.
The preparation method of the technical measures is designed for the high-power constant-temperature cable with the specific structure, is simple and easy to implement, and can reliably fill the heat-conducting silicone grease fully in the cable core with the twisted structure so as to avoid the loss of the heat-conducting silicone grease in the forming process. Meanwhile, the obtained cooling pipe has good compression resistance, bending resistance and high flexibility.
The beneficial technical effects of the invention are as follows: the technical measures aim at the particularity of the high-power cable, and the reliable heat conduction path is established between the outer wall of the power wire core and the outer wall of the cooling pipe through the heat conduction silicone grease filled in the twisting gaps of the cable core, so that the heat dissipation of the power wire core is basically not influenced by the arrangement position of the power wire core and the cooling pipe and the contact area, the heat exchange efficiency between each power wire core of the twisted structure cable core and the cooling pipe is effectively improved, the excellent heat dissipation effect is achieved, and the inside of the cable core of the high-power cable basically maintains a relatively balanced constant temperature state. In addition, the cooling pipe of the armor structure can reliably bear the influence of external impact force and cable bending force, deformation and blockage of a flow channel of the cooling medium can not occur, and the cooling medium flows smoothly.
In addition, the high-power cable adopting the technical measures meets the technical requirements of high-power current carrying, and meanwhile, the cross section structure size of the cable is formed in a miniaturized compact structure, and the flexible bending performance of each component structure is good, so that the flexible performance of the formed cable is improved, and the formed cable is convenient to flexibly arrange in a working condition environment.
Drawings
Fig. 1 is a schematic structural view of the present invention.
Fig. 2 is a schematic diagram of another embodiment of the present invention.
The meaning of the reference numerals in the figures: 1-a power wire core; 11-conductors; 12-an insulating layer; 2-a cooling pipe; 21-a silica gel base tube; 22-armor layer; 3-heat conductive silicone grease; 4-an isolating layer; 5-a sheath layer.
Detailed Description
The invention relates to the technical field of cables, in particular to a high-power constant-temperature cable and a preparation method of the cable, which are particularly suitable for charging a new energy automobile, and the technical scheme of the main body of the invention is specifically described below by combining a plurality of embodiments. Wherein, the embodiment 1 is combined with the attached drawing of the specification, namely, fig. 1, to clearly and specifically explain the technical scheme of the invention; example 2 the technical solution of the present invention is clearly and specifically explained with reference to fig. 2; other embodiments, although not drawn separately, may refer to the drawings of embodiment 1 or embodiment 2 for its main structure.
It is to be noted here in particular that the figures of the invention are schematic, which for the sake of clarity have simplified unnecessary details in order to avoid obscuring the technical solutions of the invention which contribute to the state of the art. In addition, the following expressions of "about", "substantially" and the like with respect to the number or the fitting relation mean that the existence of fitting errors, processing errors and the like which are reasonable in the industry is allowed, and the absolute number or fitting relation is not expressed literally.
Example 1
Referring to fig. 1, the high-power constant-temperature cable comprises a cable core with a composite structure, and an isolation layer 4 and a sheath layer 5 which are coated outside the cable core.
Specifically, the cable core is composed of five power wire cores 1 and two cooling pipes 2 with hollow structures, the five power wire cores 1 and the two cooling pipes 2 are stranded together in a concentric arrangement structure of 1+6, the two cooling pipes 2 are uniformly distributed and arranged in six pipeline structures around the circumference, and the two cooling pipes 2 are not adjacent in cross section. The ratio of the twisted pitch of the core is about 12 times.
Each power wire core 1 is composed of a conductor 11 formed by twisting a plurality of copper wire bundles with the diameter of about 0.10mm and an insulating layer 12 formed by extruding and coating a modified ethylene-tetrafluoroethylene copolymer outside the conductor 11. The bundle pitch diameter ratio of the conductor 11 is about 12 times. The thickness of the extrusion of the insulating layer 12 outside the conductor 11 is about 0.35mm and the concentricity of the extrusion is about 95%.
Each cooling tube 2 is composed of a silica gel base tube 21 of a hollow structure, and an armor layer 22 of a stainless steel band structure spirally wrapped around the outer periphery of the silica gel base tube 21 along the axial direction of the silica gel base tube 21. The silicone base tube 21 is a silicone rubber material extrusion molding structure with a shore hardness of about 75A, the inner diameter of the silicone base tube 21 is about 5.0mm, and the wall thickness of the silicone base tube 21 is about 1.2mm, that is, the outer diameter thereof is about 6.2mm. The armor layer 22 is a spiral wrapping structure formed by a 304 type stainless steel belt with the thickness of about 0.45mm and arranged on the periphery of the silica gel base tube 21, and the gap spacing of the spiral wrapping is about 3mm; when the armor layer 22 and the silica gel base pipe 21 are in a concentric fit state, the annular fit clearance between the inner wall of the armor layer 22 and the outer wall of the silica gel base pipe 21 is about 1.0mm.
In the above-mentioned stranding structure of the cable core, the paste-like heat-conducting silicone grease 3 having excellent heat-conducting property is filled in the stranding gap, the heat-conducting silicone grease 3 fills the stranding gap of the cable core with a full filling structure which is as free of dead angles and omission as possible, and the heat-conducting silicone grease 3 filled in the cable core passes through the spiral wrapping gap of the armor layer 22 to directly wrap the outer wall of the silica gel base tube 21. After the heat conduction silicone grease 3 is filled in place in the stranded gaps of the cable core, the heat conduction silicone grease 3 respectively coats each cooling pipe 2 and each power wire core 1 on the cross section, so that the outer wall of each cooling pipe 2 is respectively communicated with the outer wall of each power wire core 1, and a heat conduction path is established through the heat conduction silicone grease 3.
The isolation layer 4 is a self-adhesive polyimide film with the thickness of about 0.03mm, and is an overlapped wrapping structure outside the cable core, and the lap rate of the overlapped wrapping structure is about 35%, so that the heat conduction silicone grease 3 filled in the cable core is prevented from losing in the forming process.
The sheath layer 5 is made of thermoplastic elastomer material with Shore hardness of about 75A, and is an extruded structure outside the isolation layer 4. The extrusion thickness of the sheath layer 5 is about 1.4mm, and the extrusion concentricity is about 90%.
The preparation method of the high-power constant-temperature cable comprises the following process steps:
step 1, respectively forming a power wire core and a cooling pipe;
Specifically, the power wire core is formed according to the following process steps:
step I, twisting copper wires with designed quantity by adopting a wire twisting machine according to the twisting pitch diameter ratio in a concentric arrangement structure to form a twisted conductor;
Step II, heating and plasticizing the modified ethylene-tetrafluoroethylene copolymer at the temperature of about 280 ℃ by adopting an extruder;
Extruding and molding an insulating layer outside the bunched conductor in the step I in a tube extruding mode by using the heated and plasticized modified ethylene-tetrafluoroethylene copolymer according to the design size;
Preparing a power wire core for standby;
The cooling pipe is formed according to the following process steps:
① extruding a silicone rubber material into a tube according to the design size by using an extruder, wherein the temperature of a screw rod and a machine head part of the extruder is controlled to be about 35 ℃ in the process, so as to obtain a blank of the silicone base tube;
Step ②, vulcanizing the extruded silica gel base pipe blank by using steam at the temperature of about 155 ℃ to obtain a silica gel base pipe;
Step ③, adopting a steel belt spiral armoring machine to spirally cover the 304 type stainless steel belt selected above on the surface of the silica gel base pipe in step ② according to the design size;
Preparing a cooling pipe for standby;
Step 2, adopting a cabling machine to twist the five power wire cores and the two cooling pipes together in a 1+6 concentric arrangement structure according to the design structure;
In the twisting process of the power wire core and the cooling pipe, filling pasty heat-conducting silicone grease in a twisting gap in a dip-coating mode, overlapping and wrapping a cable core with the heat-conducting silicone grease by adopting a self-adhesive polyimide film, wherein the overlapping and wrapping coverage rate of the self-adhesive polyimide film is about 35%, so that the pasty heat-conducting silicone grease is prevented from losing in the cable forming process;
Step 3, heating and plasticizing the thermoplastic elastomer material at the temperature of about 180 ℃ by adopting an extruder;
The heated and plasticized thermoplastic elastomer material is extruded in a tube-extrusion manner to form a jacket layer outside the cable core of step 2, according to the above-mentioned design dimensions.
Example 2
Referring to fig. 2, the high-power constant-temperature cable comprises a cable core with a composite structure, and an isolation layer 4 and a sheath layer 5 which are coated outside the cable core.
Specifically, the cable core is composed of fifteen power wire cores 1 and four cooling pipes 2 with hollow structures, the fifteen power wire cores 1 and the four cooling pipes 2 are stranded together in a concentric arrangement structure of 1+6+12, the two cooling pipes 2 are uniformly distributed and arranged in six pipeline structures around the first layer, the other two cooling pipes 2 are uniformly distributed and arranged in twelve pipeline structures around the second layer, and the four cooling pipes 2 are not mutually adjacent in cross section. The ratio of the twisted pitch of the core is about 16 times.
Each power wire core 1 is composed of a conductor 11 formed by twisting a plurality of copper wire bundles with the diameter of about 0.08mm and an insulating layer 12 formed by extruding and coating a modified ethylene-tetrafluoroethylene copolymer outside the conductor 11. The bundle pitch diameter ratio of the conductor 11 is about 14 times. The insulation 12 is extruded to a thickness of about 0.40mm outside the conductor 11 with an extrusion concentricity of about 94%.
Each cooling tube 2 is composed of a silica gel base tube 21 of a hollow structure, and an armor layer 22 of a stainless steel band structure spirally wrapped around the outer periphery of the silica gel base tube 21 along the axial direction of the silica gel base tube 21. The silicone base tube 21 is a silicone rubber material extrusion molding structure with shore hardness of about 70A, the inner diameter of the silicone base tube 21 is about 6.0mm, and the wall thickness of the silicone base tube 21 is about 1.5mm, that is, the outer diameter thereof is about 7.5mm. The armor layer 22 is a spiral wrapping structure formed by a 304 type stainless steel belt with the thickness of about 0.5mm and arranged on the periphery of the silica gel base tube 21, and the gap spacing of the spiral wrapping is about 4mm; when the armor layer 22 and the silica gel base pipe 21 are in a concentric fit state, the annular fit clearance between the inner wall of the armor layer 22 and the outer wall of the silica gel base pipe 21 is about 0.9mm.
In the above-mentioned stranding structure of the cable core, the paste-like heat-conducting silicone grease 3 having excellent heat-conducting property is filled in the stranding gap, the heat-conducting silicone grease 3 fills the stranding gap of the cable core with a full filling structure which is as free of dead angles and omission as possible, and the heat-conducting silicone grease 3 filled in the cable core passes through the spiral wrapping gap of the armor layer 22 to directly wrap the outer wall of the silica gel base tube 21. After the heat conduction silicone grease 3 is filled in place in the stranded gaps of the cable core, the heat conduction silicone grease 3 respectively coats each cooling pipe 2 and each power wire core 1 on the cross section, so that the outer wall of each cooling pipe 2 is respectively communicated with the outer wall of each power wire core 1, and a heat conduction path is established through the heat conduction silicone grease 3.
The isolation layer 4 is a self-adhesive polyimide film with the thickness of about 0.04mm, and is an overlapped wrapping structure outside the cable core, and the overlapping rate of the overlapped wrapping structure is about 40%, so that the heat conduction silicone grease 3 filled in the cable core is prevented from losing in the forming process.
The sheath layer 5 is made of thermoplastic elastomer material with Shore hardness of about 70A, and is an extruded structure outside the isolation layer 4. The extrusion thickness of the sheath layer 5 is about 1.6mm, and the extrusion concentricity is about 92%.
The preparation method of the high-power constant-temperature cable comprises the following process steps:
step 1, respectively forming a power wire core and a cooling pipe;
Specifically, the power wire core is formed according to the following process steps:
step I, twisting copper wires with designed quantity by adopting a wire twisting machine according to the twisting pitch diameter ratio in a concentric arrangement structure to form a twisted conductor;
step II, heating and plasticizing the modified ethylene-tetrafluoroethylene copolymer at the temperature of about 300 ℃ by adopting an extruder;
Extruding and molding an insulating layer outside the bunched conductor in the step I in a tube extruding mode by using the heated and plasticized modified ethylene-tetrafluoroethylene copolymer according to the design size;
Preparing a power wire core for standby;
The cooling pipe is formed according to the following process steps:
① extruding a silicone rubber material into a tube according to the design size by using an extruder, wherein the temperature of a screw rod and a machine head part of the extruder is controlled to be about 30 ℃ in the process, so as to obtain a blank of the silicone base tube;
②, vulcanizing the silica gel base pipe blank obtained by extrusion molding by using steam at the temperature of about 160 ℃ to obtain a silica gel base pipe;
Step ③, adopting a steel belt spiral armoring machine to spirally cover the 304 type stainless steel belt selected above on the surface of the silica gel base pipe in step ② according to the design size;
Preparing a cooling pipe for standby;
Step 2, twisting fifteen power wire cores and four cooling pipes together in a 1+6+12 concentric arrangement structure by adopting a cabling machine according to the design structure;
in the twisting process of the power wire core and the cooling pipe, filling pasty heat-conducting silicone grease in a twisting gap in a dip-coating mode, overlapping and wrapping a cable core with the heat-conducting silicone grease by adopting a self-adhesive polyimide film, wherein the overlapping and wrapping coverage rate of the self-adhesive polyimide film is about 40%, so that the pasty heat-conducting silicone grease is prevented from losing in the cable forming process;
Step 3, heating and plasticizing the thermoplastic elastomer material at the temperature of about 200 ℃ by adopting an extruder;
The heated and plasticized thermoplastic elastomer material is extruded in a tube-extrusion manner to form a jacket layer outside the cable core of step 2, according to the above-mentioned design dimensions.
Example 3
The high-power constant-temperature cable comprises a cable core with a composite structure, and an isolation layer and a sheath layer which are coated outside the cable core.
Specifically, the cable core is composed of six power wire cores and a cooling pipe with a hollow structure, wherein the six power wire cores and the cooling pipe are stranded together in a 1+6 concentric arrangement structure, and the cooling pipe is used as the center. The ratio of the twisted pitch of the core is about 8 times.
Each power wire core is composed of a conductor formed by twisting a plurality of copper wire bundles with the diameter of about 0.13mm and an insulating layer formed by extruding and wrapping the modified ethylene-tetrafluoroethylene copolymer outside the conductor. The bundle lay ratio of the conductor is about 8 times. The insulation layer was extruded to a thickness of about 0.30mm outside the conductor with an extrusion concentricity of about 97%.
Each cooling tube is composed of a silica gel base tube with a hollow structure and an armor layer with a stainless steel band structure, wherein the armor layer is spirally wrapped on the periphery of the silica gel base tube along the axial direction of the silica gel base tube. The silica gel base pipe is a silicon rubber material extrusion pipe molding structure with the Shore hardness of about 80A, the inner diameter of the silica gel base pipe is about 4.5mm, the pipe wall thickness of the silica gel base pipe is about 1.3mm, namely the outer diameter of the silica gel base pipe is about 5.8mm. The armor layer is a spiral wrapping structure formed by a 304 type stainless steel belt with the thickness of about 0.4mm and arranged on the periphery of the silica gel base pipe, and the gap spacing of the spiral wrapping is about 3.5mm; when the armor layer and the silica gel base pipe are in a concentric fit state, an annular fit clearance between the inner wall of the armor layer and the outer wall of the silica gel base pipe is about 0.8mm.
In the stranding structure of the cable core, the pasty heat-conducting silicone grease with excellent heat conduction performance is filled in the stranding gap, the heat-conducting silicone grease fills the stranding gap of the cable core with a full filling structure which is free of dead angles and missing as far as possible, and the heat-conducting silicone grease filled in the cable core passes through the spiral wrapping gap of the armor layer to directly wrap the outer wall of the silica gel base tube. After the heat conduction silicone grease is filled in place in the stranded gaps of the cable core, the heat conduction silicone grease respectively coats each cooling pipe and each power wire core on the cross section, so that the outer walls of each cooling pipe are respectively communicated with the outer walls of each power wire core, and a heat conduction path is established through the heat conduction silicone grease.
The isolation layer is a self-adhesive polyimide film with the thickness of about 0.02mm, and the double-layer overlapped wrapping structure is arranged outside the cable core, and the overlapping rate of each layer of overlapped wrapping structure is about 30%, so that the heat conduction silicone grease filled in the cable core is prevented from losing in the forming process.
The sheath layer is made of thermoplastic elastomer material with Shore hardness of about 80A, and is of an extrusion structure outside the isolation layer. The extrusion thickness of the sheath layer is about 1.2mm, and the extrusion concentricity is about 93%.
The preparation method of the high-power constant-temperature cable comprises the following process steps:
step 1, respectively forming a power wire core and a cooling pipe;
Specifically, the power wire core is formed according to the following process steps:
step I, twisting copper wires with designed quantity by adopting a wire twisting machine according to the twisting pitch diameter ratio in a concentric arrangement structure to form a twisted conductor;
Step II, heating and plasticizing the modified ethylene-tetrafluoroethylene copolymer at about 265 ℃ by adopting an extruder;
Extruding and molding an insulating layer outside the bunched conductor in the step I in a tube extruding mode by using the heated and plasticized modified ethylene-tetrafluoroethylene copolymer according to the design size;
Preparing a power wire core for standby;
The cooling pipe is formed according to the following process steps:
① extruding a silicone rubber material into a tube according to the design size by using an extruder, wherein the temperature of a screw rod and a machine head part of the extruder is controlled to be about 33 ℃ in the process, so as to obtain a blank of the silicone base tube;
②, vulcanizing the silica gel base pipe blank obtained by extrusion molding by using steam at the temperature of about 150 ℃ to obtain a silica gel base pipe;
Step ③, adopting a steel belt spiral armoring machine to spirally cover the 304 type stainless steel belt selected above on the surface of the silica gel base pipe in step ② according to the design size;
Preparing a cooling pipe for standby;
Step 2, adopting a cabling machine to twist six power wire cores and one cooling pipe together in a 1+6 concentric arrangement structure according to the design structure;
In the twisting process of the power wire core and the cooling pipe, filling pasty heat-conducting silicone grease in a twisting gap in a dip-coating mode, and carrying out double-layer overlapping wrapping on a cable core with the heat-conducting silicone grease by adopting a self-adhesive polyimide film, wherein the overlapping wrapping covering rate of each layer of the self-adhesive polyimide film is about 30%, so that the pasty heat-conducting silicone grease is prevented from losing in the cable forming process;
step 3, heating and plasticizing the thermoplastic elastomer material at the temperature of about 160 ℃ by adopting an extruder;
The heated and plasticized thermoplastic elastomer material is extruded in a tube-extrusion manner to form a jacket layer outside the cable core of step 2, according to the above-mentioned design dimensions.
Example 4
The high-power constant-temperature cable comprises a cable core with a composite structure, and an isolation layer and a sheath layer which are coated outside the cable core.
Specifically, the cable core is composed of five power wire cores and two cooling pipes with hollow structures, the five power wire cores and the two cooling pipes are stranded together in a 1+6 concentric arrangement structure, the two cooling pipes are uniformly distributed and arranged in six pipeline structures around the circumference, and the two cooling pipes are not adjacent in cross section. The ratio of the twisted pitch of the core is about 14 times.
Each power wire core is composed of a conductor formed by twisting a plurality of copper wire bundles with the diameter of about 0.1mm and an insulating layer formed by extruding and wrapping the modified ethylene-tetrafluoroethylene copolymer outside the conductor. The bundle lay ratio of the conductor is about 10 times. The insulation layer was extruded to a thickness of about 0.35mm outside the conductor with an extrusion concentricity of about 96%.
Each cooling tube is composed of a silica gel base tube with a hollow structure and an armor layer with a stainless steel band structure, wherein the armor layer is spirally wrapped on the periphery of the silica gel base tube along the axial direction of the silica gel base tube. The silica gel base pipe is a silicon rubber material extrusion pipe molding structure with the Shore hardness of about 70A, the inner diameter of the silica gel base pipe is about 5.5mm, the pipe wall thickness of the silica gel base pipe is about 1.4mm, namely the outer diameter of the silica gel base pipe is about 6.9mm. The armor layer is a spiral wrapping structure formed by a 304 type stainless steel belt with the thickness of about 0.45mm and arranged on the periphery of the silica gel base pipe, and the gap spacing of the spiral wrapping is about 4mm; when the armor layer and the silica gel base pipe are in a concentric fit state, an annular fit clearance between the inner wall of the armor layer and the outer wall of the silica gel base pipe is about 1.0mm.
In the stranding structure of the cable core, the pasty heat-conducting silicone grease with excellent heat conduction performance is filled in the stranding gap, the heat-conducting silicone grease fills the stranding gap of the cable core with a full filling structure which is free of dead angles and missing as far as possible, and the heat-conducting silicone grease filled in the cable core passes through the spiral wrapping gap of the armor layer to directly wrap the outer wall of the silica gel base tube. After the heat conduction silicone grease is filled in place in the stranded gaps of the cable core, the heat conduction silicone grease respectively coats each cooling pipe and each power wire core on the cross section, so that the outer walls of each cooling pipe are respectively communicated with the outer walls of each power wire core, and a heat conduction path is established through the heat conduction silicone grease.
The isolation layer is a self-adhesive polyimide film with the thickness of about 0.03mm, and the double-layer overlapped wrapping structure is arranged outside the cable core, wherein the overlap rate of each layer of overlapped wrapping structure is about 35%, so that the heat conduction silicone grease filled in the cable core is prevented from losing in the forming process.
The sheath layer is made of thermoplastic elastomer material with Shore hardness of about 70A, and is of an extrusion structure outside the isolation layer. The extrusion thickness of the sheath layer is about 1.5mm, and the extrusion concentricity is about 94%.
The preparation method of the high-power constant-temperature cable comprises the following process steps:
step 1, respectively forming a power wire core and a cooling pipe;
Specifically, the power wire core is formed according to the following process steps:
step I, twisting copper wires with designed quantity by adopting a wire twisting machine according to the twisting pitch diameter ratio in a concentric arrangement structure to form a twisted conductor;
step II, heating and plasticizing the modified ethylene-tetrafluoroethylene copolymer at a temperature of about 275 ℃ by adopting an extruder;
Extruding and molding an insulating layer outside the bunched conductor in the step I in a tube extruding mode by using the heated and plasticized modified ethylene-tetrafluoroethylene copolymer according to the design size;
Preparing a power wire core for standby;
The cooling pipe is formed according to the following process steps:
① extruding a silicone rubber material into a tube according to the design size by using an extruder, wherein the temperature of a screw rod and a machine head part of the extruder is controlled to be about 40 ℃ in the process, so as to obtain a blank of the silicone base tube;
②, vulcanizing the extruded silica gel base pipe blank by using steam at the temperature of about 158 ℃ to obtain a silica gel base pipe;
Step ③, adopting a steel belt spiral armoring machine to spirally cover the 304 type stainless steel belt selected above on the surface of the silica gel base pipe in step ② according to the design size;
Preparing a cooling pipe for standby;
Step 2, adopting a cabling machine to twist the five power wire cores and the two cooling pipes together in a 1+6 concentric arrangement structure according to the design structure;
in the twisting process of the power wire core and the cooling pipe, filling pasty heat-conducting silicone grease in a twisting gap in a dip-coating mode, and carrying out double-layer overlapping wrapping on a cable core with the heat-conducting silicone grease by adopting a self-adhesive polyimide film, wherein the overlapping wrapping rate of each layer of the self-adhesive polyimide film is about 35%, so that the pasty heat-conducting silicone grease is prevented from running off in the cable forming process;
Step 3, heating and plasticizing the thermoplastic elastomer material at the temperature of about 170 ℃ by adopting an extruder;
The heated and plasticized thermoplastic elastomer material is extruded in a tube-extrusion manner to form a jacket layer outside the cable core of step 2, according to the above-mentioned design dimensions.
Example 5
The high-power constant-temperature cable comprises a cable core with a composite structure, and an isolation layer and a sheath layer which are coated outside the cable core.
Specifically, the cable core is composed of sixteen power wire cores and three cooling pipes with hollow structures, the sixteen power wire cores and the three cooling pipes are stranded together in a concentric arrangement structure of 1+6+12, and the three cooling pipes are uniformly distributed and arranged in six pipeline structures around the first layer, and the cooling pipes are not mutually adjacent in cross section. The ratio of the twisted pitch of the core is about 16 times.
Each power wire core is composed of a conductor formed by twisting a plurality of copper wire bundles with the diameter of about 0.10mm and an insulating layer formed by extruding and wrapping the modified ethylene-tetrafluoroethylene copolymer outside the conductor. The bundle lay ratio of the conductor is about 14 times. The insulation layer was extruded to a thickness of about 0.30mm outside the conductor with an extrusion concentricity of about 97%.
Each cooling tube is composed of a silica gel base tube with a hollow structure and an armor layer with a stainless steel band structure, wherein the armor layer is spirally wrapped on the periphery of the silica gel base tube along the axial direction of the silica gel base tube. The silica gel base pipe is a silicon rubber material extrusion pipe molding structure with the Shore hardness of about 80A, the inner diameter of the silica gel base pipe is about 6.0mm, the pipe wall thickness of the silica gel base pipe is about 1.4mm, namely the outer diameter of the silica gel base pipe is about 7.4mm. The armor layer is a spiral wrapping structure formed by a 304 type stainless steel belt with the thickness of about 0.4mm and arranged on the periphery of the silica gel base pipe, and the gap spacing of the spiral wrapping is about 3mm; when the armor layer and the silica gel base pipe are in a concentric fit state, an annular fit clearance between the inner wall of the armor layer and the outer wall of the silica gel base pipe is about 1.0mm.
In the stranding structure of the cable core, the pasty heat-conducting silicone grease with excellent heat conduction performance is filled in the stranding gap, the heat-conducting silicone grease fills the stranding gap of the cable core with a full filling structure which is free of dead angles and missing as far as possible, and the heat-conducting silicone grease filled in the cable core passes through the spiral wrapping gap of the armor layer to directly wrap the outer wall of the silica gel base tube. After the heat conduction silicone grease is filled in place in the stranded gaps of the cable core, the heat conduction silicone grease respectively coats each cooling pipe and each power wire core on the cross section, so that the outer walls of each cooling pipe are respectively communicated with the outer walls of each power wire core, and a heat conduction path is established through the heat conduction silicone grease.
The isolation layer is a self-adhesive polyimide film with the thickness of about 0.04mm, and the overlapping wrapping structure is arranged outside the cable core, so that the overlapping rate of the overlapping wrapping structure is about 50%, and the heat conduction silicone grease filled in the cable core is prevented from losing in the forming process.
The sheath layer is made of thermoplastic elastomer material with Shore hardness of about 80A, and is of an extrusion structure outside the isolation layer. The extrusion thickness of the sheath layer is about 1.6mm, and the extrusion concentricity is about 95%.
The preparation method of the high-power constant-temperature cable comprises the following process steps:
step 1, respectively forming a power wire core and a cooling pipe;
Specifically, the power wire core is formed according to the following process steps:
step I, twisting copper wires with designed quantity by adopting a wire twisting machine according to the twisting pitch diameter ratio in a concentric arrangement structure to form a twisted conductor;
step II, heating and plasticizing the modified ethylene-tetrafluoroethylene copolymer at the temperature of about 290 ℃ by adopting an extruder;
Extruding and molding an insulating layer outside the bunched conductor in the step I in a tube extruding mode by using the heated and plasticized modified ethylene-tetrafluoroethylene copolymer according to the design size;
Preparing a power wire core for standby;
The cooling pipe is formed according to the following process steps:
① extruding a silicone rubber material into a tube according to the design size by using an extruder, wherein the temperature of a screw rod and a machine head part of the extruder is controlled to be about 38 ℃ in the process, so as to obtain a blank of the silicone base tube;
②, vulcanizing the silica gel base pipe blank obtained by extrusion molding by using steam at the temperature of about 150 ℃ to obtain a silica gel base pipe;
Step ③, adopting a steel belt spiral armoring machine to spirally cover the 304 type stainless steel belt selected above on the surface of the silica gel base pipe in step ② according to the design size;
Preparing a cooling pipe for standby;
Step 2, twisting sixteen power wire cores and three cooling pipes together in a 1+6+12 concentric arrangement structure by adopting a cabling machine according to the design structure;
In the twisting process of the power wire core and the cooling pipe, filling pasty heat-conducting silicone grease in a twisting gap in a dip-coating mode, overlapping and wrapping a cable core with the heat-conducting silicone grease by adopting a self-adhesive polyimide film, wherein the overlapping and wrapping coverage rate of the self-adhesive polyimide film is about 50%, so that the pasty heat-conducting silicone grease is prevented from losing in the cable forming process;
Step 3, heating and plasticizing the thermoplastic elastomer material at the temperature of about 190 ℃ by adopting an extruder;
The heated and plasticized thermoplastic elastomer material is extruded in a tube-extrusion manner to form a jacket layer outside the cable core of step 2, according to the above-mentioned design dimensions.
The above examples are only intended to illustrate the present invention, not to limit it.
Although the invention has been described in detail with reference to the above embodiments, it will be understood by those of ordinary skill in the art that: the specific technical scheme in the embodiments can be modified or part of technical features in the specific technical scheme can be replaced equivalently; such modifications and substitutions do not depart from the spirit and scope of the invention.
Claims (10)
1. A high-power constant-temperature cable comprises a cable core with a composite structure, and an isolation layer (4) and a sheath layer (5) which are coated outside the cable core;
The cable core is formed by twisting a plurality of power wire cores (1) and at least one hollow cooling pipe (2);
the method is characterized in that:
in the stranding structure of the cable core, heat conduction silicone grease (3) is filled in the stranding gap in a full filling structure, and the heat conduction silicone grease (3) respectively coats the cooling pipe (2) and each power wire core (1) on the cross section, so that the outer wall of the cooling pipe (2) is respectively communicated with the outer wall of each power wire core (1).
2. The high power thermostatic cable according to claim 1, characterized in that:
the cable core is provided with a plurality of cooling pipes (2), the cooling pipes (2) are distributed among the twisting structures of the power cores (1), and the cooling pipes (2) are not adjacent in cross section.
3. A high power thermostatic cable according to claim 1 or 2, characterized in that:
The cooling tube (2) is composed of a silica gel base tube (21) with a hollow structure and an armor layer (22) with a stainless steel belt structure, wherein the armor layer is spirally wrapped on the periphery of the silica gel base tube (21) along the axial direction of the silica gel base tube (21);
And the heat conduction silicone grease (3) filled in the cable core passes through the spiral wrapping gap of the armor layer (22) to wrap the outer wall of the silica gel base tube (21).
4. A high power thermostatic cable according to claim 3, characterized in that:
The silica gel base pipe (21) is a silicon rubber material extrusion pipe molding structure with the Shore hardness of 70A-80A;
The inner diameter of the silica gel base tube (21) is 4.5 mm-6.0 mm;
the wall thickness of the silica gel base tube (21) is 1.2 mm-1.5 mm;
The armor layer (22) is a spiral wrapping structure formed by a 304 type stainless steel belt with the thickness of 0.4-0.5 mm, and the gap spacing of the spiral wrapping is 3-4 mm on the periphery of the silica gel base tube (21);
Under the concentric fit state of the armor layer (22) and the silica gel base pipe (21), the annular fit clearance between the inner wall of the armor layer (22) and the outer wall of the silica gel base pipe (21) is less than or equal to 1.0mm.
5. A high power thermostatic cable according to claim 1 or 2, characterized in that:
the power wire core (1) is composed of a plurality of conductors (11) formed by twisting copper wire bundles with the diameters of 0.08-0.13 mm and an insulating layer (12) formed by extruding and wrapping modified ethylene-tetrafluoroethylene copolymer outside the conductors (11);
The extrusion thickness of the insulating layer (12) is 0.30 mm-0.40 mm.
6. The high power thermostatic cable according to claim 1, characterized in that:
the isolation layer (4) is a self-adhesive polyimide film with the thickness of 0.02-0.04 mm, and is of an overlapped wrapping structure outside the cable core;
The overlapping rate of the overlapping wrapping structure is more than or equal to 30 percent.
7. The high power thermostatic cable according to claim 1, characterized in that:
the sheath layer (5) is made of thermoplastic elastomer material with the Shore hardness of 70A-80A, and is of an extrusion structure outside the isolation layer (4);
the extrusion thickness of the sheath layer (5) is 1.2 mm-1.6 mm, and the extrusion concentricity is more than or equal to 90%.
8. A method of manufacturing a high power thermostatic cable according to any one of claims 1 to 7, characterized in that the method of manufacturing comprises the following process steps:
step 1, respectively forming a power wire core and a cooling pipe;
Step 2, twisting the power wire cores and the cooling pipes with designed numbers together in a concentric arrangement structure by adopting a cabling machine, wherein the twisting pitch diameter ratio is 8-16 times;
In the twisting process of the power wire core and the cooling pipe, filling pasty heat-conducting silicone grease in twisting gaps in a dip-coating mode, and overlapping and wrapping a cable core with the heat-conducting silicone grease by adopting a self-adhesive polyimide film, wherein the overlapping and wrapping coverage rate of the self-adhesive polyimide film is more than or equal to 30%;
step 3, heating and plasticizing the thermoplastic elastomer material at 160-200 ℃ by adopting an extruder;
And (2) extruding the heated and plasticized thermoplastic elastomer material outside the cable core in the step (2) in a pipe extruding mode according to the designed size to form the sheath layer.
9. The method of claim 8, wherein the power core in step1 is formed according to the following process steps:
step I, twisting copper wires with designed quantity according to a concentric arrangement structure by adopting a wire twisting machine, wherein the twisting pitch diameter ratio is 8-14 times to form a twisted conductor;
Step II, heating and plasticizing the modified ethylene-tetrafluoroethylene copolymer at 265-300 ℃ by adopting an extruder;
And (3) extruding and molding the insulating layer outside the bundle conductor in the step I by a pipe extruding mode according to the designed size by using the heated and plasticized modified ethylene-tetrafluoroethylene copolymer.
10. The method of claim 8, wherein the cooling tube in step1 is formed according to the following process steps:
①, extruding a silicone rubber material into a tube according to a designed size by adopting an extruder, wherein the temperature of a screw rod and a machine head part of the extruder is controlled within 40 ℃ in the process, and a blank of the silicone base tube is obtained;
②, vulcanizing the silica gel base pipe blank obtained by extrusion molding by using steam at 150-160 ℃ to obtain a silica gel base pipe;
and ③, adopting a steel belt spiral armoring machine to spirally cover the selected 304-type stainless steel belt on the surface of the silica gel base pipe in the step ② according to the designed size, and obtaining the cooling pipe.
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