CN120977659A - Lightweight submarine cable structure and its electrical unit fabrication method - Google Patents
Lightweight submarine cable structure and its electrical unit fabrication methodInfo
- Publication number
- CN120977659A CN120977659A CN202511484622.0A CN202511484622A CN120977659A CN 120977659 A CN120977659 A CN 120977659A CN 202511484622 A CN202511484622 A CN 202511484622A CN 120977659 A CN120977659 A CN 120977659A
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- layer
- shielding
- copper wire
- cable structure
- submarine cable
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/14—Submarine cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
- H01B13/2613—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by longitudinal lapping
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
- H01B13/2613—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by longitudinal lapping
- H01B13/262—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by longitudinal lapping of an outer metallic screen
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/1875—Multi-layer sheaths
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/22—Metal wires or tapes, e.g. made of steel
- H01B7/226—Helicoidally wound metal wires or tapes
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B9/00—Power cables
- H01B9/02—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients
- H01B9/021—Features relating to screening tape per se
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B9/00—Power cables
- H01B9/02—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients
- H01B9/025—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients composed of helicoidally wound wire-conductors
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B9/00—Power cables
- H01B9/02—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients
- H01B9/027—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients composed of semi-conducting layers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B9/00—Power cables
- H01B9/02—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients
- H01B9/028—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients with screen grounding means, e.g. drain wires
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
- Y02A30/14—Extreme weather resilient electric power supply systems, e.g. strengthening power lines or underground power cables
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Insulated Conductors (AREA)
Abstract
The invention belongs to the technical field of submarine cables, and particularly relates to a lightweight submarine cable structure and a preparation method of an electric unit thereof, wherein the submarine cable structure comprises a three-core electric unit, the electric unit comprises a conductor layer, an insulating layer and a metal shielding layer, the metal shielding layer comprises an inner shielding layer, an outer shielding layer and an aluminum-plastic composite belt layer which are sequentially arranged from inside to outside, the axial clearance between adjacent copper wires is increased by increasing the pitch diameter ratio, the copper wires are arranged loosely, the overall flexibility of the cable is improved, the copper wire layer is not easy to deform or debond during bending, and the protection requirements on lead jackets and the like are reduced, so that the thickness of the lead jackets is favorably saved, and the weight reduction is realized; the adoption of the larger overlap ratio is beneficial to the matching of the axial increased clearance between the outer layer winding mesh belt and the copper wires, the outer layer winding mesh belt partially penetrates into the clearance, and the partial gradual transition is realized to the adjacent copper wires, so that the occlusion in a physical concave-convex form between the two layers is realized, the occlusion force is increased, and the stability is improved.
Description
Technical Field
The invention belongs to the technical field of submarine cables, and particularly relates to a lightweight submarine cable structure and a preparation method of an electric unit of the lightweight submarine cable structure.
Background
In the field of traditional offshore ultra-high voltage (generally 220 kV-500 kV) power transmission, the three-core submarine cable plays a key role and is used for large-capacity and long-distance power transmission. The traditional ultra-high pressure three-core submarine cable generally adopts a thick and heavy structure and high-density materials so as to meet the requirements of electrical performance, mechanical strength, water resistance, corrosion resistance and the like. Traditional submarine cable often uses copper conductor, and insulating layer material selection is limited, and the metal sheath adopts plumbous sheath more, and metal armor provides mechanical protection, but weight is also big to lead to submarine cable bulk weight increase and be difficult to reduce, be unfavorable for transportation and laying.
It should be noted that this section of the disclosure only provides a background related to the present disclosure, and does not necessarily constitute prior art or known technology.
Disclosure of Invention
The invention aims to provide a lightweight submarine cable structure and a preparation method of an electric unit thereof, so as to solve the problem of weight increase caused by the fact that an existing submarine cable adopts a lead sheath, an insulating layer is too thick and the like.
In order to achieve the above object, in a first aspect, the present invention provides a lightweight submarine cable structure, comprising a three-core electric unit comprising:
a conductor layer for conducting electricity to achieve power transmission;
An insulating layer, which is coated outside the conductor layer and is used for insulating the conductor layer;
The metal shielding layer is coated outside the insulating layer and used for shielding a high-voltage electric field of the conductor layer, the metal shielding layer comprises an inner shielding layer, an outer shielding layer and an aluminum-plastic composite belt layer which are sequentially arranged from inside to outside, the inner shielding layer comprises a plurality of copper wires spirally wound on the insulating layer, the pitch diameter ratio between the copper wires is 7-9:1, the outer shielding layer is a semiconductive copper wire shielding belt, the semiconductive copper wire shielding belt is wound on the inner shielding layer in a semi-lap-wrapping mode, and the lap-lap ratio of the semiconductive copper wire shielding belt is 50% -80%.
In one possible implementation manner, the winding angle of the semi-conductive copper wire shielding tape is 15-30 degrees, the width of the semi-conductive copper wire shielding tape is 60-90 mm, and the thickness of the semi-conductive copper wire shielding tape is 0.3-0.7 mm.
In one possible implementation, the volume resistivity of the semiconductive copper wire shielding tape is equal to or less than 600 Ω.
In one possible implementation, the elongation of the semiconductive copper wire shielding tape is greater than or equal to 3%.
In one possible implementation manner, the semiconductive copper wire shielding tape comprises a plurality of galvanized copper wires, the number of the galvanized copper wires is 10-30, the diameter of each galvanized copper wire is 0.1-0.3 mm, and the single weight of each galvanized copper wire is less than or equal to 460g/m 2.
In one possible implementation manner, the aluminum-plastic composite belt layer is longitudinally wrapped outside the outer shielding layer through hot melt adhesive, and the paying-off tension change range of the aluminum-plastic composite belt layer wrapping is controlled within +/-10%.
In one possible implementation, the glue yield of the hot melt glue is 0.1-0.5L/min, and the hot melt temperature is 80-120 ℃.
Optionally, the hot melt adhesive comprises at least one of the following parameters:
The softening point of the hot melt adhesive is 82-96 ℃;
the melt viscosity of the hot melt adhesive is 10000-14000 CPs;
The solidification time of the hot melt adhesive is 6-8 s;
the opening time of the hot melt adhesive is 8-10 s.
In one possible implementation, the electrical unit further comprises a non-metallic sheath, the non-metallic sheath is sleeved outside the metallic shielding layer, and the non-metallic sheath is a semiconductive polyethylene sheath.
In one possible implementation mode, the lightweight submarine cable structure further comprises an armor pad layer, an armor layer and an outer pad layer which are sequentially coated outside the three-core electric unit, a filling layer is arranged between the armor pad layer and the electric unit, and the armor pad layer and the outer pad layer are made of PP ropes.
In one possible implementation manner, the insulating layer is a polymer matrix in which nanoscale insulating reinforced particles are dispersed, the total addition amount of the nanoscale insulating reinforced particles is less than or equal to 4.5wt%, the nanoscale insulating reinforced particles comprise nano silicon dioxide particles and nano boron nitride particles, and the ratio of the nano silicon dioxide particles to the nano boron nitride particles is 4-6:1.
Optionally, the polymer matrix is a crosslinked polyethylene, and the polymer matrix comprises at least one of the following parameters:
The dielectric strength is more than or equal to 35MV/m;
dielectric loss factor is less than or equal to 5.0X10 -4;
The volume resistivity is more than or equal to 1.0X10 14 Ω.m.
In a second aspect, an embodiment of the present invention further provides a method for preparing an electrical unit, for preparing an electrical unit with a lightweight submarine cable structure according to the first aspect, where the preparation method includes:
s100, providing a conductor layer, and coating an insulating layer outside the conductor layer;
S200, spirally winding a copper wire outside an insulating layer according to a pitch diameter ratio of a preset multiple to form an inner metal shielding layer;
S300, wrapping the semi-conductive copper wire shielding tape outside the inner metal shielding layer at a preset covering rate to form an outer metal shielding layer;
s400, longitudinally wrapping the aluminum-plastic composite belt layer outside the outer shielding layer, and combining the aluminum-plastic composite belt layer and the outer shielding layer by adopting hot melt adhesive, so as to form an electric unit.
The invention has at least the following beneficial effects:
According to the lightweight submarine cable structure and the preparation method of the electric unit of the lightweight submarine cable structure, the metal shielding layer of the submarine cable structure enables copper wires to be wound more gently through increasing the pitch diameter ratio (equivalent to reducing the winding angle), the spiral line is longer, the axial gap between adjacent copper wires is increased, the copper wires are loose in arrangement, the overall flexibility of the cable is improved, the copper wire layers are not easy to deform or debond during bending, the protection requirements on lead sheaths and the like are weakened, the thickness of the lead sheaths is omitted, weight reduction is achieved, proper pitch is maintained, excessive concentration of shielding effects is avoided, meanwhile, resistance of the shielding layer is reduced, and circulation loss of shielding is reduced.
Further, the increase of the pitch diameter ratio has better shielding effect, but the larger gap of the copper wires at the inner layer can cause electric field concentration or non-uniformity; the semi-conductive copper wire shielding tape is wrapped outside the copper wire at a lap rate of at least 50%, so that an outer metal shielding layer is formed, a relatively continuous, compact and relatively smooth conductor layer is formed on the whole by adopting a relatively tight lap rate, a relatively good equipotential surface is provided for the outer tape, a more uniform radial electric field is generated on any position (including above a copper wire gap) of the outer surface of the insulating shielding layer, and the electric field uniformity is improved; the overlapping rate (50% -80% in the embodiment and optionally 52% -65%) is adopted to facilitate forming a lamination area with local lamination bulges and gradual thickness changes, so that the cooperation of the axial increasing gaps between the outer layer winding mesh belt and the copper wires is facilitated, the outer layer winding mesh belt partially penetrates into the gaps and partially gradually changes to the adjacent copper wires, the physical concave-convex form of the two layers is realized, the biting force is increased, the stability is improved, the local ripple type buffering is also realized, the deformation resistance of cables, such as bending and the like is improved, the electric field concentration or non-uniformity possibly caused by the gaps of the inner layer copper wires is greatly eliminated, the local discharge is restrained, the mesh holes of the semi-conductive copper wire shielding belt provide additional parallel paths for short-circuit current between the copper wires, and the short-circuit current paths along the copper wires, the bearing capacity of the short-circuit current is greatly improved through the transition of different conductive forms and the composite conductive forms at the two contact areas, the better electric field environment is maintained under the non-metal sheath, the better cable weight is facilitated to be reduced, the better mechanical interlocking effect can be realized, the integrity and stability of the strip layer are greatly enhanced, the strip is prevented from shifting, edge tilting or loosening during subsequent processing or cable bending, the improved shielding performance is beneficial to reducing the thickness of the inner insulating layer, and the lightweight of the cable is realized.
Furthermore, due to the fact that three phases are close to each other and symmetrical in structure, electromagnetic fields are basically offset internally, external electromagnetic radiation is small, the two ends of the metal sheath and the armor layer are usually grounded, induced current is small, operation loss is low, transmission loss is reduced, electric power cost is saved, service life is prolonged, and maintenance cost is reduced.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are needed in the description of the embodiments or the prior art will be briefly described, and it is obvious that the drawings in the description below are some embodiments of the present invention, and other drawings can be obtained according to the drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic cross-sectional view of a lightweight submarine cable structure according to an embodiment of the present invention;
fig. 2 is a schematic diagram of a specific structure of a metal shielding layer according to an embodiment of the present invention;
fig. 3 is a flowchart of a method for manufacturing an electric unit with a lightweight submarine cable structure according to an embodiment of the present invention.
In the figure, a 1-conductor layer, a 2-insulating layer, a 3-metal shielding layer, a 310-inner shielding layer, a 320-outer shielding layer, a 330-aluminum-plastic composite tape layer, a 4-nonmetal sheath, a 5-filling layer, a 6-armor layer, a 7-armor layer and an 8-outer cushion layer are arranged.
Detailed Description
The technical solutions of the present invention will be clearly and completely described in connection with the embodiments, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It will be understood by those skilled in the art that all terms (including 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 unless defined otherwise. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the prior art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The term "and/or" as used herein includes all or any element and all combination of one or more of the associated listed items.
In a first aspect, as shown in fig. 1, an embodiment of the present invention provides a lightweight submarine cable structure, which is mainly applied to ultra-high voltage power transmission, and the lightweight submarine cable structure specifically includes three-core electric units (three-core electric units refer to three electric units), and the invention adopts a tightly symmetrical three-core twisting mode, so as to reduce unnecessary filling materials and supporting structures. The single electric unit specifically comprises a conductor layer 1, an insulating layer 2 and a metal shielding layer 3 which are arranged from inside to outside. Wherein the conductor layer 1 is used for conducting electricity for power transmission. The insulating layer 2 is coated on the outside of the conductor layer 1 for insulating the conductor layer 1. The metal shielding layer 3 is coated outside the insulating layer 2 and is used for shielding the high-voltage electric field of the conductor layer 1 and carrying short-circuit fault current when the system suffers from single-phase grounding fault.
Specifically, as shown in fig. 2, the metal shielding layer 3 includes an inner shielding layer 310, an outer shielding layer 320 and an aluminum-plastic composite tape layer 330 sequentially disposed from inside to outside, the inner shielding layer 310 includes a plurality of copper wires spirally wound on the insulating layer 2, a pitch diameter ratio between the copper wires is 7-9:1, the outer shielding layer 320 is a semiconductive copper wire shielding tape, the semiconductive copper wire shielding tape is wrapped on the inner shielding layer 310 in a semi-lapping and wrapping manner, and a lapping rate of the semiconductive copper wire shielding tape is 50% -80%.
According to the embodiment of the invention, the pitch diameter ratio (the winding angle is reduced) is increased, so that the copper wires are wound more gently, the spiral line is longer, the axial gap between adjacent copper wires is increased, the copper wires are arranged loosely, the overall flexibility of the cable is improved, the copper wire layers are not easy to deform or debond during bending, the protection requirements on lead jackets and the like are reduced, the thickness of the lead jackets is omitted, weight reduction is realized, the proper pitch is maintained, the excessive concentration of shielding effects is avoided, the resistance of shielding layers is reduced, and the circulation loss of shielding is reduced.
Further, the method has the advantages that the joint diameter ratio is increased, the better shielding effect is achieved, but the electric field concentration or the non-uniformity possibly caused by a larger gap of an inner copper wire is achieved, the outer metal shielding layer is formed by wrapping the semi-conductive copper wire shielding tape outside the copper wire with a lap ratio of at least 50%, the relatively tight lap ratio is adopted, an overall relatively continuous, compact and relatively smooth conductor layer is formed, the outer tape is facilitated to provide a better equipotential surface, the electric field on the outer surface of the insulating shielding tape is ensured to have a uniform radial electric field at any position (including the upper part of the copper wire gap), the electric field uniformity is improved, the lap ratio (in the embodiment, 50% -80%, optionally 52% -65%) of the upper part of the copper wire is adopted, the overlapping area between the local overlapping bulge and the thickness gradual overlapping area is formed, the axial increasing clearance fit between the outer winding mesh tape and the copper wire is facilitated, the partial gradual transition to the adjacent copper wire is achieved, the physical occlusion force between two layers is increased, the stability is improved, the local corrugated cable bending resistance is also achieved, the current-carrying capacity of the copper wire is further improved, the current concentration of the copper wire is greatly reduced, the current-carrying capacity is further reduced, the current-carrying capacity of the copper wire is reduced, the current-carrying capacity is increased, and the current-carrying capacity is reduced, and the current-carrying capacity is increased, and the current-carrying performance is increased, and the performance is increased and the performance is reduced, and the performance is greatly the performance is reduced, and the performance is realized, better mechanical interlocking effect can be realized, the integrity and stability of the strip layer are greatly enhanced, the strip is prevented from shifting, edge tilting or loosening during subsequent processing (such as sheath extrusion) or cable bending, the improved shielding performance is beneficial to reducing the thickness of the inner insulating layer 2, and the weight reduction of the cable is realized.
In some embodiments, the winding angle of the semi-conductive copper wire shielding tape is 15-30 degrees, the width of the semi-conductive copper wire shielding tape is 60-90 mm, and the thickness of the semi-conductive copper wire shielding tape is 0.3-0.7 mm.
In this embodiment, by controlling the winding angle, the winding angle is matched with the inner layer with an increased pitch diameter ratio, and the winding angle and the inner layer have different angles which are properly staggered, so that the mechanical engagement of the inner layer and the outer layer is facilitated, the stability of the double-layer metal shielding layer 3 is improved, the possibility of moving the copper wires with large spacing is further reduced, and the like is avoided, and the winding angle is prevented from being too large or too small, because the winding angle is too large or too small, the outer layer is not beneficial to deep into the space between the inner layer copper wires, and the mechanical engagement of the inner layer and the outer layer is not beneficial to being improved, and meanwhile, the uniform electric field is also not beneficial to be obtained.
Further, controlling the proper winding width to facilitate the combination with the inner copper wire shielding layer, wherein the too wide or the too narrow is not beneficial to the clearance fit with the inner copper wire;
further, the thickness of the winding belt is controlled appropriately, so that the height of the overlapped area is controlled not to be too high or too low, interlayer combination is improved, the too high of the overlapped area can cause too large interlayer gaps of other parts of the winding belt after the winding belt penetrates into the copper wire gaps, and too small of the height of the overlapped area is unfavorable for increasing the part of the winding belt penetrating into the copper wire gaps, and both the combination between the inner layer and the outer layer and electric field uniformity are affected.
In some embodiments, the semiconductive copper wire shielding tape has a volume resistivity of 600 Ω, cm or less and a surface resistance of 1700 Ω or less.
In this embodiment, the semiconductive copper wire shielding tape with low volume resistivity and surface resistance can ensure that the shielding tape can rapidly conduct away charges, avoid local electric field distortion, reduce joule heat and avoid ablation, ensure that the contact resistance between the shielding tape and the copper wire is relatively low, and avoid heating or oxidation degradation, thereby improving the stability of the outer shielding layer 320 and further improving the shielding effect.
In some embodiments, the elongation of the semiconductive copper wire shielding tape is greater than or equal to 3%, alternatively, the elongation of the semiconductive copper wire shielding tape is less than 15%.
In the embodiment, the elongation of the semiconductive copper wire shielding tape is controlled in a proper large range, so that the adhesion between the semiconductive copper wire shielding tape and a copper wire gap can be enhanced, the mechanical engagement effect is enhanced, and the uniform electric field is facilitated.
In some embodiments, the semiconductive copper wire shielding tape comprises a plurality of galvanized copper wires, the number of the galvanized copper wires is 10-30, the diameter of the galvanized copper wires is 0.1 mm-0.3 mm, and the single weight of each galvanized copper wire is less than or equal to 460g/m 2. It is known that the semi-conductive copper wire shielding tape is provided with a shielding tape formed by semi-conductive material and galvanized copper wires, so that semi-conductive performance is realized, and the semi-conductive material is a semi-conductive polyethylene product.
In this embodiment, the number of the copper wires, the diameter of the copper wires and the control weight are optimized, so that the number and the distribution of the conductive paths in the semiconductive copper wire shielding tape are adjusted, and the mesh holes of the semiconductive copper wire shielding tape are improved to provide additional parallel paths for short-circuit current between the copper wires, thereby improving the shielding effect.
In some embodiments, the aluminum-plastic composite belt layer 330 is longitudinally wrapped outside the outer shielding layer 320 by hot melt adhesive, and the pay-off tension variation range of the wrapping of the aluminum-plastic composite belt layer 330 is controlled within ±10%, which is beneficial to ensuring the stability and the tightness of the longitudinal wrapping structure.
Optionally, the glue outlet amount of the hot melt glue is 0.1-0.5L/min, and the hot melt temperature is 80-120 ℃, for example, the hot melt temperature is 80 ℃, 100 ℃ or 120 ℃.
Optionally, the softening point of the hot melt adhesive is 82-96 ℃, such as 82-84 ℃,86 ℃,88 ℃,90 ℃,92 ℃,94 ℃ and 96 ℃.
Optionally, the melt viscosity of the hot melt adhesive is 10000-14000 CPs, for example 10000CPs,12000 CPs or 14000CPs.
Optionally, the setting time of the hot melt adhesive is 6-8 s (s represents time unit seconds), for example, the setting time can be 6s,7s or 8s.
Optionally, the hot melt adhesive has an opening time of 8-10 s, for example 8s,9s or 10s, and the opening time refers to the maximum allowable time after coating until pressing, and factors influencing the opening time include coating temperature, adhesive coating amount, ambient temperature and substrate temperature.
According to the embodiment, the fluidity of the hot melt adhesive is improved through the high hot melt adhesive temperature, the stable longitudinal wrapping tension is realized, the stable extrusion of the aluminum plastic composite belt to the composite shielding layer is realized, the tight combination of the composite shielding layer is facilitated, the stability and the electric field uniformity are improved, the shielding effect is improved, the thickness of an inner insulating layer is reduced, the light weight of a cable is realized, the fluidity of the hot melt adhesive is increased, the gap of the composite shielding layer is filled, and therefore, the combination of local copper wires and the semiconductive copper wire shielding belt is realized, the multi-angle buffering of the copper wire shielding belt in different directions and the copper wires and the flexibility of the hot melt adhesive is formed, the stability of the metal shielding layer is greatly improved, and the electric field uniformity effect is guaranteed. In addition, the glue outlet amount of the hot melt glue is controlled in the range, so that the buffer effect is improved, and the binding force between the aluminum-plastic composite tape layer of the hot melt glue and the outer shielding layer is improved by further limiting the performance parameters of the hot melt glue, so that the stability of the metal shielding layer is further facilitated.
In some embodiments, the electric unit further comprises a non-metal sheath 4, the non-metal sheath 4 is sleeved outside the metal shielding layers 3, the non-metal sheath 4 is a semi-conductive polyethylene sheath, electric connectivity of three phases of the submarine cable is guaranteed, an electric field is uniform, electric field concentration is restrained, and system fault current can be circulated and shared among the three phases of the metal shielding layers 3.
In some embodiments, the lightweight submarine cable structure further comprises an armor layer 6, an armor layer 7 and an outer cushion layer 8 which are sequentially coated outside the three-core electric unit. Specifically, the armor layer 7 adopts a hybrid armor structure of nonmagnetic high-strength fibers and light metal wires (such as stainless steel wires), high-strength fibers such as aramid fibers are used as main bearing components, good tensile strength and wear resistance are provided, the light metal wires are arranged at intervals, mechanical protection and impact resistance are enhanced, and compared with the traditional steel wire armor, the structure is reduced by 25% -35% in weight, meanwhile, eddy current loss of the armor layer 7 is greatly reduced, and the transmission efficiency of submarine cables is greatly improved. The aramid fiber is woven into a fiber layer with a certain structure through weaving equipment, and light metal wires are inserted into the aramid fiber weaving layer at certain intervals to form a hybrid armor structure. The mixed armor layer 7 is coated outside the armor cushion layer 6 by special equipment, coating tension and thickness uniformity of the armor layer 7 are controlled, tensile strength and abrasion resistance of the armor layer 7 are tested, and the submarine cable internal structure can be effectively protected.
Further, a filling layer 5 is arranged between the armor pad 6 and the electric unit, the filling layer 5 is made of a semi-conductive sector filling strip, the gap is filled with a semi-conductive filling material, partial discharge caused by an air gap is eliminated, and meanwhile, mechanical stress caused by cable bending or submarine water pressure change can be buffered, so that a cable core wire is protected, and a cloth belt is coated on the outer layer after filling in a wrapping mode to ensure the roundness of the cable.
Optionally, the materials of the armor pad 6 and the outer pad 8 are PP ropes, so that the buffering and wear-resisting effects of the submarine cable structure can be improved, and the service life of the submarine cable can be prolonged.
In some embodiments, the insulating layer 2 is a polymer matrix in which nano-sized insulating reinforcing particles are dispersed, and the total addition amount of the nano-sized insulating reinforcing particles is equal to or less than 4.5wt%.
Optionally, the nanoscale insulation reinforced particles comprise nano silicon dioxide particles and nano boron nitride particles, and the ratio of the nano silicon dioxide particles to the nano boron nitride particles is 4-6:1.
Alternatively, the polymer matrix in this example is crosslinked polyethylene (XLPE) and the polymer matrix has at least the following performance parameters of a dielectric strength of 35MV/m or more, a dielectric loss factor (at 50Hz,20 ℃) of 5.0X10 -4 or less, and a volume resistivity of 1.0X10 14. OMEGA.m or more. For example, the dielectric strength is 40 MV/m, the dielectric loss factor is less than or equal to 4.0X10 -4, and the volume resistivity is 2.0X10 14 Ω.m.
In the embodiment, the nano silicon dioxide is added into the insulating layer, so that the tensile strength and the elongation at break can be remarkably enhanced, the dielectric loss is reduced, the charge injection is inhibited, the electric field distribution is uniform, the cost is low, the nano boron nitride improves the heat conductivity, improves the electric branch starting voltage, improves the heat conduction and electric properties, the cost is relatively high, the use amount of the nano silicon dioxide is increased, better mechanical strength and uniform electric field can be obtained, meanwhile, the heat conduction and electric properties can be considered by increasing the nano boron nitride particles, the material property of the insulating layer is limited, the insulating property of the insulating layer is improved, the insulating shielding effect on the inner conductor layer is improved, and the transmission efficiency and the safety of the cable are further improved.
In a second aspect, as shown in fig. 3, an embodiment of the present invention provides a method for manufacturing an electrical unit, which is used for manufacturing the electrical unit with a lightweight submarine cable structure according to the foregoing embodiment, where the method for manufacturing an electrical unit includes the following steps S100 to S400:
s100, providing a conductor layer 1, and coating an insulating layer 2 outside the conductor layer 1.
And S200, spirally winding the copper wire outside the insulating layer 2 according to the pitch diameter ratio of a preset multiple to form an inner metal shielding layer 3.
Optionally, the pitch diameter ratio of the copper wires is 7-9:1, the pitch diameter ratio is increased (the winding angle is reduced), so that the copper wires are wound more gently, the spiral line is longer, the axial gap between adjacent copper wires is increased, the copper wires are arranged loosely, the overall flexibility of the cable is improved, the copper wire layers are not easy to deform or debond during bending, the protection requirements on lead jackets and the like are weakened, the thickness of the lead jackets is reduced, weight reduction is realized, a larger proper pitch is maintained, the excessive concentration of shielding effects is avoided, meanwhile, the resistance of shielding layers is reduced, and the circulation loss of shielding is reduced.
S300, wrapping the semi-conductive copper wire shielding tape outside the inner metal shielding layer 3 at a preset covering rate to form an outer metal shielding layer 3.
The semi-conductive copper wire shielding tape has a covering rate of 50% -80%, so that a lamination area with local lamination bulges and gradual thickness changes is formed, the outer layer winding mesh tape and copper wires are matched with each other in an axial increasing clearance, the outer layer winding mesh tape partially penetrates into the clearance and is partially and gradually transited to adjacent copper wires, the physical concave-convex type occlusion between two layers is realized, the biting force is increased, stability is improved, the local corrugated buffer is also realized, the deformation resistance of cables such as bending and the like is improved, electric field concentration or non-uniformity possibly caused by the inner layer copper wire clearance is greatly eliminated, partial discharge is restrained, meshes of the semi-conductive copper wire shielding tape provide additional parallel paths for short-circuit current among the copper wires, and the short-circuit current paths along the copper wires are greatly improved through different conductive forms and the transition of the composite conductive forms in the contact area of the two layers, the bearing capacity of the short-circuit current is greatly improved, the non-metal sheath 4 is more beneficial to maintaining a better electric field environment, the weight of the cables is beneficial to reducing, the high covering rate can be realized, the mechanical interlocking effect is greatly enhanced, the stability and the subsequent bending and the cable is prevented from being deformed or the insulation performance of the whole cable is reduced, the whole is more stable, the tape is prevented from being deformed, and the insulation performance is improved, and the insulation performance of the tape is easier to be deformed, and the inside the tape is 2.
S400, longitudinally wrapping the aluminum-plastic composite belt layer 330 outside the outer shielding layer 320, and combining the aluminum-plastic composite belt layer 330 with the outer shielding layer 320 by adopting hot melt adhesive, so as to form an electric unit.
It should be noted that, the embodiment of the invention only describes the preparation method of a single electric unit, three core electric units (three electric units are symmetrically arranged) are arranged in the whole submarine cable structure, then filling is carried out, and finally, the inner electric units are protected by preparing structures such as an armor layer 7.
In the description of the present invention, it should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like indicate orientations or positional relationships based on the orientation or positional relationships shown in the drawings, merely to facilitate describing the present invention and simplify the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present invention.
The terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include one or more such feature. In the description of the present invention, unless otherwise indicated, the meaning of "a plurality" is two or more.
In the description of the present invention, unless explicitly stated and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected, directly connected, or indirectly connected through an intermediary, or may be in communication with the interior of two elements. The specific meanings of the above terms in the present invention can be understood in specific situations by those of ordinary skill in the art. In the description of the present specification, a particular feature, structure, material, or characteristic may be combined in any suitable manner in one or more embodiments or examples.
It should be noted that the above embodiments are merely for illustrating the technical solution of the present invention and not for limiting the same, and although the present invention has been described in detail with reference to the above embodiments, it should be understood by those skilled in the art that the technical solution described in the above embodiments may be modified or some or all of the technical features may be equivalently replaced, and these modifications or substitutions do not make the essence of the corresponding technical solution deviate from the scope of the technical solution of the embodiments of the present invention.
Claims (13)
1. A lightweight submarine cable structure comprising a three-core electrical unit, characterized in that the electrical unit comprises:
a conductor layer for conducting electricity to achieve power transmission;
An insulating layer, which is coated outside the conductor layer and is used for insulating the conductor layer;
The metal shielding layer is coated outside the insulating layer and used for shielding a high-voltage electric field of the conductor layer, the metal shielding layer comprises an inner shielding layer, an outer shielding layer and an aluminum-plastic composite belt layer which are sequentially arranged from inside to outside, the inner shielding layer comprises a plurality of copper wires spirally wound on the insulating layer, the pitch diameter ratio between the copper wires is 7-9:1, the outer shielding layer is a semiconductive copper wire shielding belt, the semiconductive copper wire shielding belt is wound on the inner shielding layer in a semi-lap-wrapping mode, and the lap-lap ratio of the semiconductive copper wire shielding belt is 50% -80%.
2. The lightweight submarine cable structure according to claim 1, wherein the winding angle of the semiconductive copper wire shielding tape is 15-30 degrees, the width of the semiconductive copper wire shielding tape is 60-90 mm, and the thickness of the semiconductive copper wire shielding tape is 0.3-0.7 mm.
3. The lightweight submarine cable structure according to claim 1, wherein the volume resistivity of the semiconductive copper wire shielding tape is no more than 600 Ω.cm, and the surface resistance is no more than 1700 Ω.
4. The lightweight submarine cable structure according to claim 1, wherein the elongation of the semiconducting copper wire shielding tape is greater than or equal to 3%.
5. The lightweight submarine cable structure according to claim 1, wherein the semiconductive copper wire shielding tape comprises a plurality of galvanized copper wires, the number of the galvanized copper wires is 10-30, the diameter of the galvanized copper wires is 0.1-0.3 mm, and the single weight of each galvanized copper wire is less than or equal to 460g/m 2.
6. The lightweight submarine cable structure according to claim 1, wherein the aluminum-plastic composite tape layer is longitudinally wrapped outside the outer shielding layer through hot melt adhesive, and the paying-off tension change range of the aluminum-plastic composite tape layer is controlled within +/-10%.
7. The lightweight submarine cable structure according to claim 6, wherein the glue outlet amount of the hot melt glue is 0.1-0.5 l/min, and the hot melt temperature is 80-120 ℃.
8. The lightweight submarine cable structure according to claim 7, wherein said hot melt adhesive comprises at least one of the following parameters:
The softening point of the hot melt adhesive is 82-96 ℃;
the melt viscosity of the hot melt adhesive is 10000-14000 CPs;
The solidification time of the hot melt adhesive is 6-8 s;
the opening time of the hot melt adhesive is 8-10 s.
9. The lightweight submarine cable structure according to any one of claims 1 to 8, wherein said electrical unit further comprises a non-metallic sheath that is sleeved outside of said metallic shielding layer, said non-metallic sheath being a semiconductive polyethylene sheath.
10. The lightweight submarine cable structure according to claim 9, further comprising an armor layer, an armor layer and an outer cushion layer which are sequentially coated outside the three-core electric unit, wherein a filling layer is arranged between the armor layer and the electric unit, and the armor layer and the outer cushion layer are made of PP ropes.
11. The lightweight submarine cable structure according to claim 10, wherein the insulating layer is a polymer matrix in which nanoscale insulating reinforcing particles are dispersed, and the total addition amount of the nanoscale insulating reinforcing particles is equal to or less than 4.5wt%;
the nanoscale insulation reinforced particles comprise nano silicon dioxide particles and nano boron nitride particles, and the ratio of the nano silicon dioxide particles to the nano boron nitride particles is 4-6:1.
12. The lightweight submarine cable structure according to claim 11, wherein said polymer matrix is cross-linked polyethylene, and said polymer matrix comprises at least one of the following parameters:
The dielectric strength is more than or equal to 35MV/m;
dielectric loss factor is less than or equal to 5.0X10 -4;
The volume resistivity is more than or equal to 1.0X10 14 Ω.m.
13. A method of manufacturing an electrical unit for manufacturing a lightweight submarine cable structure according to any one of claims 1 to 12, the method comprising:
s100, providing a conductor layer, and coating an insulating layer outside the conductor layer;
S200, spirally winding a copper wire outside an insulating layer according to a pitch diameter ratio of a preset multiple to form an inner metal shielding layer;
s300, wrapping the semi-conductive copper wire shielding tape outside the inner metal shielding layer at a preset covering rate to form an outer metal shielding layer;
s400, longitudinally wrapping the aluminum-plastic composite belt layer outside the outer shielding layer, and combining the aluminum-plastic composite belt layer and the outer shielding layer by adopting hot melt adhesive, so as to form an electric unit.
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| CN120656786A (en) * | 2025-08-20 | 2025-09-16 | 国网湖北省电力有限公司襄阳供电公司 | Ultra-high conductive wire and cable and preparation method thereof |
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| CN107742547A (en) * | 2017-10-09 | 2018-02-27 | 天津金山电线电缆股份有限公司 | A kind of high voltage control and power integration cable and preparation method thereof |
| CN218768791U (en) * | 2021-11-18 | 2023-03-28 | 上海起帆电缆股份有限公司 | Light environment-friendly submarine cable |
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