Elastic composite shielding cable for ships and preparation process thereof

Abstract

The invention discloses an elastic composite shielding cable for a ship and a preparation process thereof, and aims to solve the problems of poor environmental adaptability, low shielding effectiveness, insufficient elasticity and unstable process of an existing ship cable. The cable sequentially comprises a conductor layer, an insulating layer, a composite shielding layer and a sheath layer from inside to outside, wherein the conductor layer is formed by twisting a plurality of strands of superfine tinned oxygen-free annealed copper wires, and two 1500D aromatic polyamide fiber elastic cores are arranged in the center of the conductor layer; the insulating layer is made of ethylene propylene rubber or thermoplastic elastomer, and the dielectric constant is not more than 3.0; the composite shielding layer is of a double-layer structure of aluminum-plastic composite tape wrapping and tinned copper wire weaving, and the shielding effectiveness of the X wave band is larger than or equal to 30 dB. The sheath layer is of a chloroprene rubber or polyurethane double-layer structure, tests such as C5-M-grade salt mist are carried out, the preparation process comprises the steps of conductor twisting, insulation extrusion, composite shielding forming and the like, various parameters are accurately controlled, the bending radius of the cable is smaller than or equal to 6D, and the cable is stable in performance after being repeatedly bent for 1000 times, low in smoke, halogen-free, flame-retardant, adaptive to severe environments of ships, stable in process and high in reliability. And reliable operation of ship equipment can be ensured.

Description

Technical Field

[0001] This invention relates to the field of cable technology, specifically to a resilient composite shielded cable for ships and its manufacturing process. Background Technology

[0002] Current shipboard cables need to be adapted to the special environment of ships, facing multiple technical challenges. Existing products cannot fully meet these requirements, as detailed below: 1. **Insufficient environmental adaptability:** Ships are exposed to high salt spray, alternating high and low temperatures (-40℃~85℃), and strong vibration (10~2000Hz) environments for extended periods. Ordinary cable sheaths are prone to corrosion and cracking, and conductors are easily oxidized. They cannot pass the stringent C5-M level salt spray test. Under extreme temperature changes, their elasticity and insulation performance degrade rapidly, affecting their service life.

[0003] 2. Low electromagnetic shielding effectiveness: Ship radar and communication equipment are densely packed, resulting in strong electromagnetic interference. Traditional single-shielded cables (such as copper wire braided cables) have a shielding effectiveness of less than 20dB in the X-band (8-12GHz), which cannot block high-frequency interference, leading to signal transmission distortion and affecting the normal operation of equipment.

[0004] 3. Poor elasticity and mechanical properties: The space for wiring inside the ship's cabin is small, requiring cables to have a small bending radius (≤6D) and the ability to withstand repeated bending. However, the conductors of ordinary cables are mostly single strands of hard copper or thick copper wires twisted together. After 1,000 bends, sheath cracks are likely to appear, the insulation resistance will drop by more than 15%, and the tensile and abrasion resistance is weak (the wear amount after 1,000 revolutions of the Taibo abrasion often exceeds 10mg).

[0005] 4. Safety compliance not met: Some cables do not meet the requirements for low smoke halogen-free flame retardancy. When burning, the smoke density exceeds 75% and the gas pH value is <4.3, which poses a fire hazard. In addition, the dielectric constant of the insulation layer is >3.0, resulting in large power transmission loss. They cannot pass the AC3.0kV spark test and are prone to breakdown accidents.

[0006] 5. **Poor process stability:** In the existing manufacturing process, uneven conductor stranding tension can easily lead to eccentricity, insulation extrusion thickness deviation exceeding ±0.1mm, and improper control of shielding layer wrapping overlap rate and braiding tension can easily result in loose strands and broken wires, leading to low product performance consistency and difficulty in guaranteeing the pass rate during mass production. Summary of the Invention

[0007] To address the shortcomings of existing technologies, this invention provides a resilient composite shielded cable for ships and its manufacturing process.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a flexible composite shielded cable for ships, comprising, from the inside out, a conductor layer, an insulation layer, a composite shielding layer, and a sheath layer; The conductor layer is a multi-strand ultra-fine tin-plated oxygen-free soft copper wire stranded structure with a copper wire diameter of 0.1-0.3mm and a stranding pitch of 10-40 times the conductor diameter. Two 1500D aramid fiber elastic cores are set in the center of the conductor. The insulation layer is made of ethylene propylene diene monomer (EPDM) or thermoplastic elastomer (TPE), with an insulation resistance constant ≥1MΩ·km at (20±5)℃ and a dielectric constant ≤3.0; The composite shielding layer is a double-layer structure of "aluminum-plastic composite tape wrapping + tinned copper wire braiding". The aluminum-plastic composite tape wrapping overlap rate is 15-25%, the tinned copper wire diameter is 0.1-0.2mm, the braiding coverage rate is ≥88%, and the braiding angle is 30-60°. The sheath layer is a double-layer structure of neoprene rubber (CR) or polyurethane (PU), with an inner sheath thickness of 0.5-1.0 mm and an outer sheath thickness of 0.8-1.2 mm. The sheath tensile strength is ≥12.5 MPa, and it passes the C5-M level salt spray test, the -40℃~85℃ high and low temperature cycle test, and the AC3.0kV spark test without breakdown.

[0009] Preferably, the coating thickness of the ultrafine tin-plated oxygen-free soft copper wire is ≥1.5μm, and the resistivity at 20℃ is ≤0.017241Ω・mm² / m.

[0010] Preferably, the ethylene propylene rubber of the insulating layer contains a peroxide crosslinking agent, an antioxidant, and a magnesium hydroxide flame retardant, with a crosslinking degree ≥85%; the thermoplastic elastomer contains a plasticizer and a compatibilizer, with an elastic recovery rate ≥90%.

[0011] Preferably, the aluminum-plastic composite strip of the composite shielding layer has an aluminum foil + polyester film composite structure, with an aluminum foil thickness ≥ 0.01 mm and a polyester film thickness ≥ 0.02 mm; the braiding tension of the tin-plated copper wire is controlled at 5-10 N to avoid loose strands or broken wires.

[0012] Preferably, the chloroprene rubber of the sheath layer contains vulcanizing agents, ozone inhibitors, and ultraviolet absorbers, and its oil resistance meets the requirement that the volume change rate after immersion in oil at 80°C for 168 hours is ≤10%; the hardness of the polyurethane is controlled at Shore A60-80 degrees, and its abrasion resistance meets the requirement that the wear amount after 1000 revolutions in the Tuber abrasion test is ≤5mg.

[0013] Preferably, the bending radius of the cable is ≤6 times the cable diameter, there are no cracks in its appearance after repeated bending 1000 times, the insulation resistance decrease rate is ≤10%, and the shielding effectiveness is ≥30dB in the X-band (8-12GHz).

[0014] Preferably, the manufacturing process of the resilient composite shielded cable for ships includes the following steps: (1) Conductor stranding: The untwisting stranding process is adopted, with an untwisting angle of 15-30°. During stranding, the tension of each copper wire is uniformly controlled at 3-8N. After stranding, pre-deformation treatment is performed. (2) Insulation extrusion: Use a rubber extruder, EPDM extrusion temperature 120-150℃, TPE extrusion temperature 180-220℃, the die adopts a coat hanger type die head, after extrusion, crosslinking is carried out by steam or irradiation, crosslinking temperature 160-180℃, crosslinking time 10-30min; (3) Composite shielding molding: First, use a high-precision wrapping machine to wrap the aluminum-plastic composite tape at a wrapping angle of 15-30° and a tension of 2-5N; then use a high-speed braiding machine to braid tin-plated copper wire at a braiding speed of 300-500r / min. After braiding, conduct a shielding layer conductivity test. (4) Sheath extrusion: Use a large length-to-diameter ratio extruder, CR extrusion temperature 130-160℃, PU extrusion temperature 180-220℃, after extrusion, water cooling + air cooling composite cooling, cooling rate 5-10℃ / s, and surface lubricant coating after cooling. (5) Finished product inspection: The cable is tested for insulation resistance, withstand voltage, shielding effectiveness, bending performance and environmental adaptability. After passing the test, it is rolled up and packaged.

[0015] Preferably, the pre-deformation treatment in step (1) is performed by roller pressing with a pressure of 5-15 MPa, which causes the copper wire to undergo 0.5-1.0% plastic deformation, thereby improving its flexibility.

[0016] Preferably, in step (2), after the insulation is extruded, the insulation thickness is monitored in real time using an online laser thickness gauge, and the thickness deviation is controlled within ±0.05mm; after crosslinking, an aging test is performed, and the elastic recovery rate remains ≥85% after 70℃×24h.

[0017] Preferably, in step (4), the sheath extrusion die is a streamlined design with a die size accuracy of ±0.02mm; the finished product inspection also includes combustion performance testing, with vertical flame spread ≤250mm, smoke density ≤75%, combustion gas pH value ≥4.3, and electrical conductivity ≤10μS / mm.

[0018] Compared with the prior art, the present invention provides a resilient composite shielded cable for ships and its manufacturing process, which has the following beneficial effects: 1. The elastic composite shielded cable for ships and its manufacturing process: The conductor is made of ultra-fine tin-plated oxygen-free soft copper wire with a resistivity of ≤0.017241Ω・mm² / m at 20℃, and is resistant to oxidation and salt spray corrosion; the sheath is a neoprene / polyurethane double-layer structure with a tensile strength ≥12.5MPa. It can pass the C5-M level salt spray test, the high and low temperature cycle test from -40℃ to 85℃, and the volume change rate after immersion in oil at 80℃ for 168h is ≤10%, ensuring long-term stable operation in the harsh environment of ships.

[0019] 2. The elastic composite shielded cable for ships and its manufacturing process: The composite shielding layer adopts a double-layer structure of "aluminum-plastic composite tape wrapping + tinned copper wire braiding". The braiding tension is controlled at 5-10N to avoid defects. The shielding effectiveness in the X-band is ≥30dB, which effectively blocks electromagnetic interference, prevents signal leakage, and is suitable for the dense electromagnetic environment of ships.

[0020] 3. The elastic composite shielded cable for ships and its manufacturing process: The conductor has two 1500D aramid fiber elastic cores at its center, the copper wire diameter is 0.1-0.3mm, the stranding pitch is 10-40 times the conductor diameter, and it is pre-deformed by roll forming. The cable bending radius is ≤6D. After repeated bending 1000 times, there are no cracks in the appearance and the insulation resistance decrease rate is ≤10%. The polyurethane sheath has a Shore hardness of A60-80 degrees, and the wear amount after 1000 Tuber abrasion revolutions is ≤5mg. The bending resistance, wear resistance and tensile strength are greatly improved.

[0021] 4. The elastic composite shielded cable for ships and its manufacturing process include magnesium hydroxide flame retardant added to the insulation layer, and the sheath meets the requirements of low smoke and halogen-free: vertical flame spread ≤250mm, smoke density ≤75%, combustion gas pH value ≥4.3, and conductivity ≤10μS / mm; the dielectric constant of the insulation layer ≤3.0, and the insulation resistance constant (20±5℃) ≥1MΩ・km. It can pass the AC3.0kV spark test without breakdown, eliminating fire and electrical safety hazards.

[0022] 5. The elastic composite shielded cable for ships and its manufacturing process employ untwisting stranding, online laser thickness measurement, streamlined sheath molds, and water-cooling + air-cooling composite cooling, with precise and controllable parameters for each process; finished product testing covers all dimensions such as insulation, shielding, bending, and environmental adaptability, resulting in a high pass rate in mass production and ensuring stable product performance. Detailed Implementation

[0023] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0024] A flexible composite shielded cable for ships, comprising, from the inside out, a conductor layer, an insulation layer, a composite shielding layer, and a sheath layer; The conductor layer employs a multi-strand ultra-fine tin-plated oxygen-free soft copper wire stranded structure, with the copper wire diameter precisely controlled within the range of 0.1-0.3mm. This specification ensures both excellent conductivity and enhanced cable flexibility. The stranding pitch is designed to be 10-40 times the conductor diameter, optimizing the cable's mechanical and electrical properties. Furthermore, two innovative 1500D aramid fiber elastic cores are placed at the center of the conductor. Aramid fibers possess high strength and low elongation, enhancing the cable's tensile strength and providing necessary elastic cushioning to withstand the complex vibration environment of ships. The insulation layer is made of ethylene propylene diene monomer (EPDM) rubber or thermoplastic elastomer (TPE), both of which have excellent electrical insulation properties and weather resistance. At an ambient temperature of (20±5)℃, the insulation resistance constant is ≥1MΩ・km, ensuring reliable insulation capability of the cable under normal operating temperatures; the dielectric constant is ≤3.0, effectively reducing signal loss during transmission and improving the signal transmission quality of the cable. The composite shielding layer adopts a double-layer structure design of "aluminum-plastic composite tape wrapping + tinned copper wire braiding". When wrapping the aluminum-plastic composite tape, the overlap rate is strictly controlled at 15-25%. Through reasonable overlap settings, the shielding effect against electromagnetic interference is effectively improved; the tinned copper wire diameter is 0.1-0.2mm, the braiding coverage is ≥88%, and the braiding angle is between 30-60°. This combination of braiding parameters not only enhances the integrity and continuity of the shielding layer but also gives it good flexibility and mechanical strength, effectively resisting external electromagnetic interference and ensuring stable signal transmission within the cable. The sheath is a double-layer structure of neoprene rubber (CR) or polyurethane (PU). The inner sheath thickness is set at 0.5-1.0 mm, and the outer sheath thickness is 0.8-1.2 mm. The double-layer structure design ensures sufficient mechanical protection while reducing the overall weight of the cable. The sheath tensile strength is ≥12.5 MPa, exhibiting good tensile and tear resistance. Furthermore, the sheath has passed the stringent C5-M level salt spray test, enabling long-term stable operation in high salt spray corrosive environments; it has passed high and low temperature cycling tests from -40℃ to 85℃, adapting to temperature variations in different sea environments; and it passed the AC3.0kV spark test without breakdown, ensuring the insulation reliability of the sheath.

[0025] The coating thickness of the ultra-fine tin-plated oxygen-free soft copper wire is strictly controlled to ≥1.5μm, ensuring excellent anti-oxidation and anti-corrosion performance in complex ship environments and effectively extending the service life of the cable. Its resistivity at a standard test temperature of 20℃ is ≤0.017241Ω・mm² / m, ensuring that the cable maintains extremely low loss during power transmission and meeting the stringent requirements of ship power systems for efficient and stable transmission.

[0026] The insulation layer uses ethylene propylene rubber as the base material, with peroxide crosslinking agents added to promote the crosslinking reaction of the rubber molecular chains, antioxidants added to inhibit oxidative degradation of the material during processing and use, and magnesium hydroxide flame retardant added to improve flame retardant performance. After processing, the degree of crosslinking of the insulation layer is ≥85%, ensuring excellent heat resistance and mechanical stability. In the thermoplastic elastomer, plasticizers are added to improve the material's flexibility and processing performance, and compatibilizers are added to enhance the compatibility between components. After optimized formulation, the elastic recovery rate of the thermoplastic elastomer is ≥90%, ensuring that the cable can quickly return to its initial state after bending deformation, improving service life and reliability.

[0027] The composite shielding layer uses a double-layer composite structure of aluminum foil and polyester film. The aluminum foil serves as the core shielding layer, with a thickness strictly controlled to ≥0.01mm to ensure excellent shielding effectiveness against electromagnetic interference. The polyester film, as a protective layer, has a thickness of at least ≥0.02mm, effectively enhancing the mechanical strength and chemical stability of the aluminum foil and preventing damage or oxidation during use. Furthermore, in the tin-plated copper wire braiding process, a precision tension control system strictly controls the braiding tension within the range of 5-10N. This tension setting has been verified through extensive experimentation and effectively avoids quality defects such as loose strands and broken wires in the tin-plated copper wire, ensuring the integrity and electrical performance of the shielding layer.

[0028] The sheath layer is made of high-performance composite material, in which a vulcanizing agent, ozone inhibitor, and UV absorber are added to the chloroprene rubber matrix in a specific ratio. Through optimized formula design and mixing process, its oil resistance reaches industry-leading standards: after 168 hours of continuous immersion in oil at 80℃, the volume change rate is strictly controlled to ≤10%, effectively resisting the erosion of common media such as mineral oil and hydraulic oil. The polyurethane component, through precise control of molecular chain structure and crosslinking density, maintains a stable hardness within the Shore A60-80 range, combining excellent flexibility and mechanical strength. Verified by the Tuber wear test, under high-speed friction conditions of 1000 rpm, the wear amount is ≤5mg, demonstrating excellent wear and tear resistance, effectively extending the cable's service life and meeting the stringent requirements of complex operating environments on ships. The chloroprene rubber of the sheath layer contains vulcanizing agents, ozone inhibitors, and ultraviolet absorbers. Its oil resistance meets the requirement that the volume change rate after immersion in oil at 80℃ for 168 hours is ≤10%. The hardness of the polyurethane is controlled at Shore A60-80 degrees, and its abrasion resistance meets the requirement that the wear amount after 1000 revolutions in the Tuber abrasion test is ≤5mg.

[0029] The cable possesses excellent bending performance and electrical stability, with specific parameters as follows: Bending performance: The minimum bending radius of the cable is designed not to exceed 6 times its own diameter. In rigorous testing simulating real-world usage scenarios, after 1000 repeated bending cycles, no visible cracks were found on the surface of the cable's outer sheath and insulation layer, demonstrating excellent fatigue resistance. Insulation performance: After 1000 repeated bending tests, the cable insulation resistance reduction rate is strictly controlled within 10%, ensuring the electrical insulation reliability during long-term use. Shielding effectiveness: In the electromagnetic environment of the X-band (8-12GHz), the cable shielding effectiveness reaches the standard of ≥30dB, effectively blocking external electromagnetic interference and preventing internal signal leakage, meeting the usage requirements of the complex electromagnetic environment of ships.

[0030] A manufacturing process for a resilient composite shielded cable for ships includes the following steps: (1) Conductor stranding: The untwisting stranding process is adopted, with an untwisting angle of 15-30°. During stranding, the tension of each copper wire is uniformly controlled at 3-8N. After stranding, pre-deformation treatment is performed. (2) Insulation extrusion: Use a rubber extruder, EPDM extrusion temperature 120-150℃, TPE extrusion temperature 180-220℃, the die adopts a coat hanger type die head, after extrusion, crosslinking is carried out by steam or irradiation, crosslinking temperature 160-180℃, crosslinking time 10-30min; (3) Composite shielding molding: First, use a high-precision wrapping machine to wrap the aluminum-plastic composite tape at a wrapping angle of 15-30° and a tension of 2-5N; then use a high-speed braiding machine to braid tin-plated copper wire at a braiding speed of 300-500r / min. After braiding, conduct a shielding layer conductivity test. (4) Sheath extrusion: Use a large length-to-diameter ratio extruder, CR extrusion temperature 130-160℃, PU extrusion temperature 180-220℃, after extrusion, water cooling + air cooling composite cooling, cooling rate 5-10℃ / s, and surface lubricant coating after cooling. (5) Finished product inspection: The cable is tested for insulation resistance, withstand voltage, shielding effectiveness, bending performance and environmental adaptability. After passing the test, it is rolled up and packaged. In step (1), the pre-deformation process is carried out by roller pressing with a pressure of 5-15 MPa, which causes the copper wire to undergo 0.5-1.0% plastic deformation, thereby improving its flexibility. In step (2), after the insulation is extruded, the insulation thickness is monitored in real time using an online laser thickness gauge, and the thickness deviation is controlled within ±0.05mm; after crosslinking, an aging test is performed, and the elastic recovery rate remains ≥85% after 70℃×24h. In step (4), the sheath extrusion die is designed with a streamlined shape and the die size accuracy is ±0.02mm. The finished product inspection also includes combustion performance testing, with vertical flame spread ≤250mm, smoke density ≤75%, combustion gas pH value ≥4.3, and electrical conductivity ≤10μS / mm.

[0031] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A flexible composite shielded cable for ships, characterized in that, From the inside out, it includes a conductor layer, an insulating layer, a composite shielding layer, and a sheath layer; The conductor layer is a multi-strand ultra-fine tin-plated oxygen-free soft copper wire stranded structure with a copper wire diameter of 0.1-0.3mm and a stranding pitch of 10-40 times the conductor diameter. Two 1500D aramid fiber elastic cores are set in the center of the conductor. The insulating layer is made of ethylene propylene rubber or thermoplastic elastomer, with an insulation resistance constant ≥1MΩ・km at (20±5)℃ and a dielectric constant ≤3.0; The composite shielding layer is a double-layer structure of "aluminum-plastic composite tape wrapping + tinned copper wire braiding". The aluminum-plastic composite tape wrapping overlap rate is 15-25%, the tinned copper wire diameter is 0.1-0.2mm, the braiding coverage rate is ≥88%, and the braiding angle is 30-60°. The sheath layer is a double-layer structure of neoprene rubber or polyurethane, with an inner sheath thickness of 0.5-1.0 mm and an outer sheath thickness of 0.8-1.2 mm. The sheath tensile strength is ≥12.5 MPa, and it passes the C5-M level salt spray test, the -40℃~85℃ high and low temperature cycle test, and the AC3.0kV spark test without breakdown.

2. The elastic composite shielded cable for ships according to claim 1, characterized in that, The coating thickness of the ultrafine tin-plated oxygen-free soft copper wire is ≥1.5μm, and the resistivity at 20℃ is ≤0.017241Ω・mm² / m.

3. The elastic composite shielded cable for ships according to claim 1, characterized in that, The insulating layer contains ethylene propylene rubber with added peroxide crosslinking agent, antioxidant and magnesium hydroxide flame retardant, with a crosslinking degree ≥85%; the thermoplastic elastomer contains added plasticizer and compatibilizer, with an elastic recovery rate ≥90%.

4. The elastic composite shielded cable for ships according to claim 1, characterized in that, The aluminum-plastic composite strip of the composite shielding layer has an "aluminum foil + polyester film" composite structure, with an aluminum foil thickness ≥0.01mm and a polyester film thickness ≥0.02mm; the braiding tension of the tin-plated copper wire is controlled at 5-10N to avoid loose strands or broken wires.

5. The elastic composite shielded cable for ships according to claim 1, characterized in that, The chloroprene rubber of the sheath layer contains vulcanizing agents, ozone inhibitors, and ultraviolet absorbers. Its oil resistance meets the requirement that the volume change rate after immersion in oil at 80℃ for 168 hours is ≤10%. The hardness of the polyurethane is controlled at Shore A60-80 degrees, and its abrasion resistance meets the requirement that the wear amount after 1000 revolutions in the Tuber abrasion test is ≤5mg.

6. The elastic composite shielded cable for ships according to claim 1, characterized in that, The cable's bending radius is ≤6 times the cable diameter, it shows no cracks after being repeatedly bent 1000 times, and its insulation resistance decreases by ≤10%; its shielding effectiveness is ≥30dB in the X-band.

7. The manufacturing process of the shipboard elastic composite shielded cable according to any one of claims 1-6, characterized in that, Includes the following steps: Step (1) Conductor stranding: The untwisting stranding process is adopted, with an untwisting angle of 15-30°. During stranding, the tension of each copper wire is uniformly controlled at 3-8N. After stranding, pre-deformation treatment is performed. Step (2) Insulation extrusion: Use a rubber extruder, EPDM extrusion temperature 120-150℃, TPE extrusion temperature 180-220℃, the die adopts a coat hanger type die head, after extrusion, crosslinking is carried out by steam or irradiation, crosslinking temperature 160-180℃, crosslinking time 10-30min; Step (3) Composite shielding molding: First, use a high-precision wrapping machine to wrap the aluminum-plastic composite tape at a wrapping angle of 15-30° and a tension of 2-5N; then use a high-speed braiding machine to braid tin-plated copper wire at a braiding speed of 300-500r / min. After braiding, conduct a shielding layer conductivity test. Step (4) Sheath extrusion: Use a large length-to-diameter ratio extruder, CR extrusion temperature 130-160℃, PU extrusion temperature 180-220℃, after extrusion, use water cooling + air cooling composite cooling, cooling rate 5-10℃ / s, and after cooling, apply surface lubricant. Step (5) Finished product inspection: The cable is tested for insulation resistance, withstand voltage, shielding effectiveness, bending performance and environmental adaptability. After passing the test, it is rolled up and packaged.

8. The manufacturing process according to claim 7, characterized in that, In step (1), the pre-deformation process is carried out by roller pressing with a pressure of 5-15 MPa, which causes the copper wire to undergo 0.5-1.0% plastic deformation, thereby improving its flexibility.

9. The manufacturing process according to claim 7, characterized in that, In step (2), after the insulation is extruded, the insulation thickness is monitored in real time using an online laser thickness gauge, and the thickness deviation is controlled within ±0.05mm; after crosslinking, an aging test is performed, and the elastic recovery rate remains ≥85% after 70℃×24h.

10. The manufacturing process according to claim 7, characterized in that, In step (4), the sheath extrusion die is designed with a streamlined shape and the die size accuracy is ±0.02mm. The finished product inspection also includes combustion performance testing, with vertical flame spread ≤250mm, smoke density ≤75%, combustion gas pH value ≥4.3, and electrical conductivity ≤10μS / mm.