Overcoming Core Technological Barriers in Conductors | The Patent for a Novel Compact Compressed Twisted Conductor Has Been Officially Approved

On June 12,2026, the National Intellectual Property Administration officially published Shanghai Shenghua Cable Technology Group's new invention patent titled "A Compact Compressed Twisted Conductor, Compressed Twisting Device and Method" (Publication No.:CN122201885A), marking a key technological breakthrough for Shenghua Cable in precision cable conductor manufacturing and providing next-generation high-performance conductor solutions for advanced power cables used in photovoltaics, energy storage, ultra-high voltage systems, and combined heat and power applications.

The conductor serves as the core medium for transmitting electrical energy in power cables. Traditional round single-filament stranded compression manufacturing processes exhibit significant limitations: the conventional compression coefficient is only around 90%, there are large gaps between individual filaments and grooves on the conductor surface, and during insulation extrusion, materials tend to embed into these gaps, resulting in uneven insulation thickness and irregular electric field distribution. Prolonged operation leads to excessive heating and aging, significantly reducing cable service life, making them unsuitable for high-load, demanding applications such as large-scale renewable energy installations and long-distance power transmission.

To address industry challenges, Shenghua Cable's R&D team conducted multiple rounds of process optimization and innovatively adopted a tile-shaped integrated twisted compression structure for special-shaped single wires. By completely reengineering the production process—from material shaping and twist arrangement to mold compression—they achieved significant breakthroughs in several key performance metrics：

1.Extreme tight filling: The copper wires interlock tightly, with the gap between conductor wires maintained within 0.05 mm and a compression coefficient exceeding 97%, far surpassing conventional industry standards.

2.Zero grooves on the conductor surface: After forming, the outer wall of the conductor is smooth and regular, eliminating the uneven grooves found in traditional stranded wires and preventing localized stress concentration in the insulation layer.

3.Conductive losses are significantly reduced: The conductor contact area is significantly increased, resulting in reduced contact resistance and lower operational heat generation, delivering outstanding long-term energy-saving performance for power transmission.

4.Cost reduction, efficiency improvement, and lightweight design: With the same current-carrying capacity, the conductor has a smaller outer diameter, reducing raw material consumption for insulation and sheathing, shrinking the overall cable volume, and lowering storage and installation costs.

  According to the Group's Technology Research Institute, this patented technology is fully compatible with a comprehensive range of products including photovoltaic DC cables, energy storage converter cables, high-voltage power cables, and power plant control cables. Building on the group's recent successful bids for new energy projects such as the Guoneng Thermal Power Plant and the Kubuqi Photovoltaic Base, the innovative conductor manufacturing process will be rapidly deployed across major production facilities for mass production, significantly enhancing the stability and service life of Shenghua's high-end cable products to meet the long-term operational safety requirements of large-scale wind and solar power bases as well as advanced power systems.

  As a national high-tech enterprise and a specialized, refined, distinctive, and innovative company, Shanghai Shenghua Electric has consistently increased its R&D investment in cable fundamental materials and structural technologies. The company currently holds a total of 77 patents covering core areas such as conductors, fire-resistant and flame-retardant cables, and cables for special equipment, establishing a comprehensive system of independent intellectual property rights. Leveraging its headquarters in Shanghai and manufacturing bases across Henan and Harbin nationwide, the group continues to drive the transformation and upgrading of the cable industry through technological innovation, utilizing its self-developed core technologies to support the high-quality development of new power systems and new energy infrastructure.

  The successful commercialization of this patented invention for compactly compressed stranded conductors represents a significant achievement in Shenghua Cable's commitment to advancing fundamental material technologies and fostering new forms of productivity. Moving forward, the group will accelerate the industrial application of these patent innovations while simultaneously upgrading specialized equipment for stranded conductor production. This initiative aims to consistently deliver higher-performance, safer, and more reliable cable products for sectors including State Grid, renewable energy generation, industrial manufacturing, and rail transit, thereby solidifying the company's technological leadership in the high-end specialty cable market.