Flexible abrasion-resistant cable and method for its production

Abstract

This invention discloses a flexible wear-resistant cable and its preparation method, relating to the field of cable technology. The cable, from the inside out, comprises a stranded tin-plated copper conductor, an irradiated cross-linked polyolefin insulation layer, a polyester fiber buffer layer, and a wear-resistant composite sheath layer. The wear-resistant composite sheath layer uses a fluorosilicone thermoplastic polyester elastomer, hydrogenated styrene elastomer SEEPS, and vinyl acrylate rubber as the composite matrix. The cross-linking agent is a mixture of bis(1-vinylimidazolium-2-)one and tripropylene glycol diacrylate in a 1:(1-3) ratio, which synergistically regulates the cross-linking performance. The preparation method includes conductor stranding annealing, insulation layer extrusion irradiation, buffer layer wrapping, double-layer sheath extrusion, and steam vulcanization. This invention achieves a synergistic improvement in flexibility and wear resistance, and exhibits excellent fatigue resistance, insulation performance, and structural stability. It is suitable for high-frequency reciprocating cable chain applications in industrial automation, and the preparation process is controllable, facilitating industrial production.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a flexible wear-resistant cable and its preparation method. Background Technology

[0002] As a core component in industrial automation, drag chain cables are mainly used in drag chain systems. They undergo high-frequency, long-stroke reciprocating bending and dragging motions along with the drag chain. At the same time, they must withstand friction and wear between the inner wall of the drag chain and adjacent cables, as well as the influence of complex working conditions such as equipment vibration and changes in ambient temperature. Therefore, the cables have extremely high requirements for flexibility, wear resistance, fatigue resistance and structural stability. Their performance directly determines the operational stability and service life of industrial equipment.

[0003] Currently, existing drag chain cables generally suffer from the technical challenge of balancing flexibility and abrasion resistance: to improve abrasion resistance, most cables use thicker sheaths or select high-hardness abrasion-resistant materials, but this leads to a decrease in cable flexibility, an increase in bending radius, and an inability to adapt to high-frequency reciprocating motion in confined spaces. Long-term use can easily result in problems such as sheath cracking and insulation damage. If the focus is on improving flexibility, using fine-gauge conductors and soft sheath materials will result in insufficient cable abrasion resistance. During the reciprocating friction of the drag chain, the sheath is prone to rapid wear and thinning, and may even expose the conductor, causing safety hazards such as short circuits and leakage, which seriously affects the normal operation of the equipment.

[0004] In addition, the manufacturing process parameters of existing cables are not precise enough, the formula design of the sheath material is unreasonable, and there is a lack of targeted modification treatment. As a result, the wear resistance, aging resistance and fatigue resistance of the cables cannot meet the long-term use requirements of high-end industrial equipment. The service life is generally short and frequent replacement is required, which increases the production cost and maintenance workload of enterprises.

[0005] To address the aforementioned issues, invention patent document CN109671523B discloses a high-temperature resistant and wear-resistant flexible cable. The cable comprises a core, a wrapping layer, and a sheath layer, arranged sequentially from the inside out. The sheath layer is made of modified silicone rubber material. This modified silicone rubber material comprises 77-85 parts silicone rubber, 12-20 parts mica flakes, and 0-3 parts inorganic antimony compound and / or inorganic germanium compound. However, while the modified silicone rubber sheath possesses high-temperature resistance, its flexibility and wear resistance durability still require further improvement. Furthermore, the conductor stranding structure and layer bonding design are not optimized, making it prone to sheath cracking, core loosening, and delamination after long-term high-frequency bending. Therefore, it remains unsuitable for the demanding high-frequency reciprocating motion of industrial automation equipment's cable chains.

[0006] Therefore, developing a drag chain cable with high flexibility, high wear resistance and stable manufacturing process and its manufacturing method is of great practical significance for improving the operational reliability of industrial automation equipment. Summary of the Invention

[0007] The purpose of this invention is to overcome the shortcomings of existing drag chain cables, such as difficulty in achieving both flexibility and wear resistance, poor fatigue resistance, and short service life, and to provide a flexible wear-resistant cable and its preparation method. This cable achieves a synergistic improvement in flexibility and wear resistance through optimized structural design, improved material formulation and preparation process, while also possessing excellent fatigue resistance, insulation and structural stability.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows: a flexible wear-resistant cable, comprising, from the inside out: stranded tin-plated copper conductor, irradiated cross-linked polyolefin insulation layer, polyester fiber buffer layer, and wear-resistant composite sheath layer; the wear-resistant composite sheath layer is made of the following raw materials in parts by weight: 35-45 parts of fluorinated silicone thermoplastic polyester elastomer, 20-25 parts of hydrogenated styrene elastomer SEEPS, 15-20 parts of vinyl acrylate rubber, 5-8 parts of ultra-high molecular weight polyethylene micro powder, 3-6 parts of nano silica, 1-2 parts of coupling agent, 2-4 parts of self-lubricating composite agent, 1.5-2.5 parts of maleic anhydride graft compatibilizer, 1.0-1.8 parts of weather stabilizer, 0.4-0.8 parts of antioxidant, 0.5-1 part of lubricant, 0.4-0.7 parts of peroxide cross-linking agent, and 0.3-0.5 parts of co-cross-linking agent.

[0009] Preferably, there are no special requirements for the source of the fluorinated silicone thermoplastic polyester elastomer. In one embodiment of the present invention, the fluorinated silicone thermoplastic polyester elastomer is made according to the method of Example 1 in the invention patent document CN109535408B.

[0010] Preferably, the hydrogenated styrene elastomer SEEPS is SEPTON. TM 4044SEEPS.

[0011] Preferably, the vinyl acrylate rubber is DUPONT Vamac GLS AEM.

[0012] Preferably, the ultra-high molecular weight polyethylene micro powder has the product number 022 and is provided by Jiangsu Zhongjiang Polymer Co., Ltd.

[0013] Preferably, the average particle size of the nano-silica is 20-40 nm.

[0014] Preferably, the coupling agent is at least one of silane coupling agent KH550, silane coupling agent KH560, and silane coupling agent KH570.

[0015] Preferably, the self-lubricating composite agent is a mixture of silicone powder and fluorinated graphite in a 1:1 mass ratio; the silicone powder is VtecLAP SC001 silicone powder, provided by Shanghai Fushen New Material Technology Co., Ltd.; and the fluorinated graphite is FG08, provided by Suzhou Cangmu New Material Co., Ltd.

[0016] Preferably, the maleic anhydride graft compatibilizer is maleic anhydride-grafted polyethylene 900E.

[0017] Preferably, the weather stabilizer is a mixture of light stabilizer UV-3346 and ultraviolet absorber UV-329 in a mass ratio of 1:(0.8-1.2).

[0018] Preferably, the antioxidant is at least one of antioxidant 1010 and antioxidant 168.

[0019] Preferably, the lubricant is zinc stearate.

[0020] Preferably, the peroxide crosslinking agent is dicumyl peroxide.

[0021] Preferably, the crosslinking agent is a compound of bis(1-vinylimidazol-2-)one and tripropylene glycol diacrylate in a mass ratio of 1:(1-3).

[0022] Preferably, the irradiated crosslinked polyolefin insulating layer is made from the following raw materials in parts by weight: 60-70 parts of ethylene-vinyl acetate copolymer, 20-30 parts of low-density polyethylene, 5-8 parts of flexible plasticizer, 0.3-0.5 parts of antioxidant 1010, 0.2-0.4 parts of ultraviolet absorber UV-327, and 1.5-2.0 parts of trimethylolpropane triacrylate.

[0023] Preferably, the ethylene-vinyl acetate copolymer is ethylene-vinyl acetate copolymer EVA1828, provided by Hanwha Chemical.

[0024] Preferably, the grade of the low-density polyethylene is 2102-TN00.

[0025] Preferably, the flexible plasticizer is a compound of dibutyl phthalate and epoxidized soybean oil in a mass ratio of 1:(0.8-1.2).

[0026] Preferably, the polyester fiber buffer layer is made of 120D polyester fiber woven tape with a thickness of 0.1mm and a wrapping overlap rate of 20%.

[0027] Preferably, the stranded tin-plated copper conductor is made of 0.15mm tin-plated copper wire, which meets the requirements of Category 5 soft copper conductors in IEC 60228 standard.

[0028] Another object of the present invention is to provide a method for preparing the flexible wear-resistant cable, comprising the following steps: Step S1, stranded conductor preparation: 0.15mm tin-plated copper wire is stranded at a pitch ratio of 12:1 to obtain a Class 5 soft copper conductor that conforms to the IEC 60228 standard. After stranding, annealing treatment is performed to improve the conductor's flexibility. Step S2, Insulation Layer Extrusion and Irradiation Crosslinking: Add the insulation layer raw materials to a high-speed mixer according to the formula and stir for 5 minutes. Then, send the mixture to a twin-screw extruder for melt blending. The extrusion temperature range is 130-160℃. Extrude the molten material onto the outside of the conductor. The extrusion thickness is controlled at 0.8 mm. Send the extruded insulated wire core into an electron irradiation device and perform irradiation crosslinking with a dose of 15 kGy to improve the mechanical strength and heat resistance of the insulation layer. Step S3, Buffer layer wrapping: Polyester fiber braided tape is wrapped around the outside of the insulated wire core using a wrapping machine. The wrapping tension is controlled at 10N and the overlap rate is maintained at 20%, which plays a role in buffering bending stress. Step S4, Double-layer sheath extrusion: A dual-extruder synchronous extrusion process is adopted. First, the inner flexible matrix layer is extruded through the first extruder, with the extrusion temperature controlled at 140-170℃ and the extrusion thickness at 1.2mm. After the inner sheath cools down to below 100℃, the outer wear-resistant modified layer is extruded through the second extruder, with the extrusion temperature controlled at 160-190℃ and the extrusion thickness at 0.8mm. The interpenetration of the molten surface layers is used to improve the bonding strength of the two sheaths. Step S5, Steam vulcanization post-treatment: The extruded semi-finished cable is sent into a steam vulcanizing tank and vulcanized at 110℃ and 0.3MPa pressure for 30 minutes to allow the rubber matrix to complete cross-linking and curing, thereby improving the mechanical properties of the sheath layer. Then, it is naturally cooled to room temperature and wound up.

[0029] Preferably, the annealing temperature in step S1 is 180-220℃, and the holding time is 1-2 hours.

[0030] Due to the application of the above technical solution, the present invention has the following beneficial effects: (1) The flexible wear-resistant cable and its preparation method disclosed in this invention effectively solve the technical bottleneck of existing drag chain cables where flexibility and wear resistance are difficult to balance. Through layered structure collaborative design and optimization of special material formula, both are improved simultaneously. Compared with the inherent contradiction in the prior art that "thickening the sheath to improve wear resistance will reduce flexibility, while thinning the soft sheath to maintain flexibility will reduce wear resistance", this invention adopts a layered structure of stranded tin-plated copper conductor, irradiated cross-linked polyolefin insulation layer, polyester fiber buffer layer and wear-resistant composite sheath layer. With the precise ratio of raw materials in each layer, the cable has both excellent flexibility (bending radius can adapt to high-frequency reciprocating motion in narrow spaces) and outstanding wear resistance. It completely solves the safety hazards such as sheath cracking, insulation layer damage and conductor exposure caused by long-term high-frequency bending, and is significantly better than the performance of the prior art.

[0031] (2) The flexible wear-resistant cable and its preparation method disclosed in this invention achieve synergistic performance enhancement through multi-component synergistic modification, and its technical effect far exceeds that of existing solutions using single materials or simple compounding. The sheath layer uses fluorinated silicone thermoplastic polyester elastomer, hydrogenated styrene elastomer SEEPS and vinyl acrylate rubber as composite matrix, combined with functional components such as ultra-high molecular weight polyethylene micro powder, nano silica and self-lubricating composite agent, which not only utilizes the complementary properties of each matrix material to improve the flexibility and wear-resistant base performance of the sheath, but also solves the technical problem of poor compatibility between different components through precise control of coupling agent and compatibilizer, so that the sheath layer has excellent wear resistance, anti-aging properties, flexibility and structural stability.

[0032] (3) The flexible wear-resistant cable and its preparation method disclosed in this invention further enhance the comprehensive performance of the cable by optimizing the preparation process parameters and co-designing the process, achieving a dual improvement in structural stability and performance consistency. During the preparation process, the conductor is annealed at a specific temperature and time after stranding to effectively eliminate stranding stress and improve conductor flexibility and structural density; the insulation layer is cross-linked by precise dosage of electron irradiation after extrusion, which significantly improves the mechanical strength and heat resistance of the insulation layer and avoids insulation layer damage caused by high-frequency bending; the buffer layer is wrapped with specific parameters to effectively buffer bending stress and reduce the stress on the sheath layer; the synergy between the simultaneous extrusion of the double sheath and the steam vulcanization post-treatment not only improves the bonding strength of the inner and outer sheaths and avoids delamination, but also enables the sheath layer to achieve full cross-linking and curing, further optimizing wear resistance and fatigue resistance.

[0033] (4) The flexible wear-resistant cable and its preparation method disclosed in this invention achieve a tight bond between the conductor, insulation layer, buffer layer and sheath layer through the adaptive design and process optimization of each structural layer. After long-term high-frequency bending, there is no loosening of the cable core, cracking of the sheath and delamination. At the same time, the optimized formula of the insulation layer and sheath layer gives the cable excellent insulation performance and weather resistance, which can adapt to complex working conditions such as equipment vibration and changes in ambient temperature, effectively improving the operational reliability of industrial automation equipment. This invention does not require complex production equipment, the preparation process is stable and controllable, and it is easy to carry out large-scale industrial production. Compared with the prior art, it improves performance without increasing production costs, and has significant technical advantages and market application value.

[0034] (5) The flexible wear-resistant cable and its preparation method disclosed in this invention use 35-45 parts of fluorinated silicone thermoplastic polyester elastomer, 20-25 parts of hydrogenated styrene elastomer SEEPS and 15-20 parts of vinyl acrylate rubber as a composite matrix. This ratio is precisely adjusted to achieve complementary performance and optimal synergy of the three elastomer materials. The three are compounded in the above ratio, which effectively avoids the performance shortcomings of a single matrix material, and lays the core foundation for the sheath layer to "balance flexibility and wear resistance", producing a technical effect of "1+1+1>3"; combined with ultra-high molecular weight polyethylene micro powder, nano silica and self-lubricating The sheath contains functional components such as a slip compound, combined with a specific crosslinking agent system. This crosslinking agent is a mixture of bis(1-vinylimidazol-2-)one and tripropylene glycol diacrylate in a mass ratio of 1:(1-3). This system allows for precise control of the crosslinking reaction rate and density of the sheath layer, avoiding problems such as poor wear resistance and tear resistance due to insufficient crosslinking, or increased rigidity and decreased flexibility due to excessive crosslinking, thus further optimizing the overall performance of the sheath layer. The synergistic effect of bis(1-vinylimidazol-2-)one and tripropylene glycol diacrylate effectively improves wear resistance and flexibility. Furthermore, the precise control of coupling agents and compatibilizers solves the technical challenge of poor compatibility between different components, enabling the sheath layer to possess excellent wear resistance, anti-aging properties, and structural stability. Detailed Implementation

[0035] The following description is intended to disclose the invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art. Example 1

[0036] A flexible wear-resistant cable comprises, from the inside out: stranded tin-plated copper conductor, irradiated cross-linked polyolefin insulation layer, polyester fiber buffer layer, and wear-resistant composite sheath layer; the wear-resistant composite sheath layer is made of the following raw materials in parts by weight: 35 parts of fluorinated silicone thermoplastic polyester elastomer, 20 parts of hydrogenated styrene elastomer SEEPS, 15 parts of vinyl acrylate rubber, 5 parts of ultra-high molecular weight polyethylene micro powder, 3 parts of nano silica, 1 part of coupling agent, 2 parts of self-lubricating composite agent, 1.5 parts of maleic anhydride graft compatibilizer, 1.0 part of weather stabilizer, 0.4 parts of antioxidant, 0.5 parts of lubricant, 0.4 parts of peroxide cross-linking agent, and 0.3 parts of co-cross-linking agent.

[0037] The fluorinated silicone thermoplastic polyester elastomer was prepared according to the method of Example 1 in invention patent document CN109535408B; the hydrogenated styrene elastomer SEEPS was SEPTON. TM 4044SEEPS; the vinyl acrylate rubber is DUPONT Vamac GLS AEM; the ultra-high molecular weight polyethylene micro powder has product number 022 and is provided by Jiangsu Zhongjiang Polymer Co., Ltd.; the average particle size of the nano-silica is 20nm; the coupling agent is silane coupling agent KH550; the self-lubricating composite agent is a mixture of silicone powder and fluorinated graphite in a 1:1 mass ratio; the silicone powder is VtecLAPSC001 and is provided by Shanghai Fushen New Material Technology Co., Ltd.; the fluorinated graphite is grade FG08 and is provided by Suzhou Cangmu New Material Co., Ltd. The materials are provided by [Company Name]; the maleic anhydride graft compatibilizer is maleic anhydride grafted polyethylene 900E; the weather stabilizer is a mixture of light stabilizer UV-3346 and ultraviolet absorber UV-329 in a mass ratio of 1:0.8; the antioxidant is antioxidant 1010; the lubricant is zinc stearate; the peroxide crosslinking agent is dicumyl peroxide; the co-crosslinking agent is a mixture of bis(1-vinylimidazol-2-)one and tripropylene glycol diacrylate in a mass ratio of 1:1.

[0038] The irradiated cross-linked polyolefin insulation layer is made from the following raw materials in parts by weight: 60 parts ethylene-vinyl acetate copolymer, 20 parts low-density polyethylene, 5 parts flexible plasticizer, 0.3 parts antioxidant 1010, 0.2 parts ultraviolet absorber UV-327, and 1.5 parts trimethylolpropane triacrylate; the ethylene-vinyl acetate copolymer is ethylene-vinyl acetate copolymer EVA1828, provided by Hanwha Chemical; the low-density polyethylene is grade 2102-TN00; the flexible plasticizer is a compound of dibutyl phthalate and epoxidized soybean oil in a mass ratio of 1:0.8; the polyester fiber buffer layer is made of 120D polyester fiber braided tape with a thickness of 0.1mm and a wrapping overlap rate of 20%; the stranded tin-plated copper conductor is made of 0.15mm tin-plated copper wire, which meets the requirements of IEC 60228 standard Class 5 soft copper conductor.

[0039] A method for preparing the aforementioned flexible abrasion-resistant cable includes the following steps: Step S1, stranded conductor preparation: 0.15mm tin-plated copper wire is stranded at a pitch ratio of 12:1 to obtain a Class 5 soft copper conductor that conforms to the IEC 60228 standard. After stranding, annealing treatment is performed to improve the conductor's flexibility. Step S2, Insulation Layer Extrusion and Irradiation Crosslinking: Add the insulation layer raw materials to a high-speed mixer according to the formula and stir for 5 minutes. Then, send the mixture to a twin-screw extruder for melt blending. The extrusion temperature range is 130-160℃. Extrude the molten material onto the outside of the conductor. The extrusion thickness is controlled at 0.8 mm. Send the extruded insulated wire core into an electron irradiation device and perform irradiation crosslinking with a dose of 15 kGy to improve the mechanical strength and heat resistance of the insulation layer. Step S3, Buffer layer wrapping: Polyester fiber braided tape is wrapped around the outside of the insulated wire core using a wrapping machine. The wrapping tension is controlled at 10N and the overlap rate is maintained at 20%, which plays a role in buffering bending stress. Step S4, Double-layer sheath extrusion: A dual-extruder synchronous extrusion process is adopted. First, the inner flexible matrix layer is extruded through the first extruder, with the extrusion temperature controlled at 140-170℃ and the extrusion thickness at 1.2mm. After the inner sheath cools down to below 100℃, the outer wear-resistant modified layer is extruded through the second extruder, with the extrusion temperature controlled at 160-190℃ and the extrusion thickness at 0.8mm. The interpenetration of the molten surface layers is used to improve the bonding strength of the two sheaths. Step S5, Steam vulcanization post-treatment: The extruded semi-finished cable is sent into a steam vulcanizing tank and vulcanized at 110℃ and 0.3MPa pressure for 30 minutes to allow the rubber matrix to complete cross-linking and curing, thereby improving the mechanical properties of the sheath layer. Then, it is naturally cooled to room temperature and wound up.

[0040] The annealing temperature in step S1 is 180°C, and the holding time is 1 hour. Example 2

[0041] A flexible wear-resistant cable comprises, from the inside out: stranded tin-plated copper conductor, irradiated cross-linked polyolefin insulation layer, polyester fiber buffer layer, and wear-resistant composite sheath layer; the wear-resistant composite sheath layer is made of the following raw materials in parts by weight: 37 parts of fluorinated silicone thermoplastic polyester elastomer, 22 parts of hydrogenated styrene elastomer SEEPS, 16 parts of vinyl acrylate rubber, 6 parts of ultra-high molecular weight polyethylene micro powder, 4 parts of nano silica, 1.2 parts of coupling agent, 2.5 parts of self-lubricating composite agent, 1.8 parts of maleic anhydride graft compatibilizer, 1.2 parts of weathering stabilizer, 0.5 parts of antioxidant, 0.6 parts of lubricant, 0.5 parts of peroxide cross-linking agent, and 0.35 parts of co-cross-linking agent.

[0042] The fluorinated silicone thermoplastic polyester elastomer was prepared according to the method of Example 1 in invention patent document CN109535408B; the hydrogenated styrene elastomer SEEPS was SEPTON. TM 4044SEEPS; the vinyl acrylate rubber is DUPONT Vamac GLS AEM; the ultra-high molecular weight polyethylene micro powder has product number 022 and is provided by Jiangsu Zhongjiang Polymer Co., Ltd.; the average particle size of the nano-silica is 25nm; the coupling agent is silane coupling agent KH560; the self-lubricating composite agent is a mixture of silicone powder and fluorinated graphite in a 1:1 mass ratio; the silicone powder is VtecLAPSC001 and is provided by Shanghai Fushen New Material Technology Co., Ltd.; the fluorinated graphite is grade FG08 and is provided by Suzhou Cangmu New Material Co., Ltd. The materials are provided by [Company Name]; the maleic anhydride graft compatibilizer is maleic anhydride grafted polyethylene 900E; the weather stabilizer is a mixture of light stabilizer UV-3346 and ultraviolet absorber UV-329 in a mass ratio of 1:0.9; the antioxidant is antioxidant 168; the lubricant is zinc stearate; the peroxide crosslinking agent is dicumyl peroxide; the co-crosslinking agent is a mixture of bis(1-vinylimidazol-2-)one and tripropylene glycol diacrylate in a mass ratio of 1:1.5.

[0043] The irradiated cross-linked polyolefin insulation layer is made from the following raw materials in parts by weight: 63 parts ethylene-vinyl acetate copolymer, 23 parts low-density polyethylene, 6 parts flexible plasticizer, 0.35 parts antioxidant 1010, 0.25 parts ultraviolet absorber UV-327, and 1.7 parts trimethylolpropane triacrylate; the ethylene-vinyl acetate copolymer is ethylene-vinyl acetate copolymer EVA1828, provided by Hanwha Chemical; the low-density polyethylene is grade 2102-TN00; the flexible plasticizer is a compound of dibutyl phthalate and epoxidized soybean oil in a mass ratio of 1:0.9; the polyester fiber buffer layer is made of 120D polyester fiber braided tape with a thickness of 0.1mm and a wrapping overlap rate of 20%; the stranded tin-plated copper conductor is made of 0.15mm tin-plated copper wire, which meets the requirements of IEC 60228 standard Class 5 soft copper conductor.

[0044] A method for preparing the aforementioned flexible abrasion-resistant cable includes the following steps: Step S1, stranded conductor preparation: 0.15mm tin-plated copper wire is stranded at a pitch ratio of 12:1 to obtain a Class 5 soft copper conductor that conforms to the IEC 60228 standard. After stranding, annealing treatment is performed to improve the conductor's flexibility. Step S2, Insulation Layer Extrusion and Irradiation Crosslinking: Add the insulation layer raw materials to a high-speed mixer according to the formula and stir for 5 minutes. Then, send the mixture to a twin-screw extruder for melt blending. The extrusion temperature range is 130-160℃. Extrude the molten material onto the outside of the conductor. The extrusion thickness is controlled at 0.8 mm. Send the extruded insulated wire core into an electron irradiation device and perform irradiation crosslinking with a dose of 15 kGy to improve the mechanical strength and heat resistance of the insulation layer. Step S3, Buffer layer wrapping: Polyester fiber braided tape is wrapped around the outside of the insulated wire core using a wrapping machine. The wrapping tension is controlled at 10N and the overlap rate is maintained at 20%, which plays a role in buffering bending stress. Step S4, Double-layer sheath extrusion: A dual-extruder synchronous extrusion process is adopted. First, the inner flexible matrix layer is extruded through the first extruder, with the extrusion temperature controlled at 140-170℃ and the extrusion thickness at 1.2mm. After the inner sheath cools down to below 100℃, the outer wear-resistant modified layer is extruded through the second extruder, with the extrusion temperature controlled at 160-190℃ and the extrusion thickness at 0.8mm. The interpenetration of the molten surface layers is used to improve the bonding strength of the two sheaths. Step S5, Steam vulcanization post-treatment: The extruded semi-finished cable is sent into a steam vulcanizing tank and vulcanized at 110℃ and 0.3MPa pressure for 30 minutes to allow the rubber matrix to complete cross-linking and curing, thereby improving the mechanical properties of the sheath layer. Then, it is naturally cooled to room temperature and wound up.

[0045] The annealing temperature in step S1 is 190°C, and the holding time is 1.2 hours. Example 3

[0046] A flexible wear-resistant cable comprises, from the inside out: stranded tin-plated copper conductor, irradiated cross-linked polyolefin insulation layer, polyester fiber buffer layer, and wear-resistant composite sheath layer; the wear-resistant composite sheath layer is made of the following raw materials in parts by weight: 40 parts of fluorinated silicone thermoplastic polyester elastomer, 23 parts of hydrogenated styrene elastomer SEEPS, 18 parts of vinyl acrylate rubber, 6.5 parts of ultra-high molecular weight polyethylene micro powder, 4.5 parts of nano-silica, 1.5 parts of coupling agent, 3 parts of self-lubricating composite agent, 2 parts of maleic anhydride graft compatibilizer, 1.5 parts of weathering stabilizer, 0.6 parts of antioxidant, 0.75 parts of lubricant, 0.55 parts of peroxide cross-linking agent, and 0.4 parts of co-cross-linking agent.

[0047] The fluorinated silicone thermoplastic polyester elastomer was prepared according to the method of Example 1 in invention patent document CN109535408B; the hydrogenated styrene elastomer SEEPS was SEPTON. TM 4044SEEPS; the vinyl acrylate rubber is DUPONT Vamac GLS AEM; the ultra-high molecular weight polyethylene micro powder has product number 022 and is provided by Jiangsu Zhongjiang Polymer Co., Ltd.; the average particle size of the nano-silica is 30nm; the coupling agent is silane coupling agent KH570; the self-lubricating composite agent is a mixture of silicone powder and fluorinated graphite in a 1:1 mass ratio; the silicone powder is VtecLAPSC001 and is provided by Shanghai Fushen New Material Technology Co., Ltd.; the fluorinated graphite is grade FG08 and is provided by Suzhou Cangmu New Material Co., Ltd. The materials are provided by [Company Name]; the maleic anhydride graft compatibilizer is maleic anhydride-grafted polyethylene 900E; the weather stabilizer is a mixture of light stabilizer UV-3346 and ultraviolet absorber UV-329 in a 1:1 mass ratio; the antioxidant is antioxidant 1010; the lubricant is zinc stearate; the peroxide crosslinking agent is dicumyl peroxide; the co-crosslinking agent is a mixture of bis(1-vinylimidazol-2-)one and tripropylene glycol diacrylate in a 1:2 mass ratio.

[0048] The irradiated cross-linked polyolefin insulation layer is made from the following raw materials in parts by weight: 65 parts ethylene-vinyl acetate copolymer, 25 parts low-density polyethylene, 6.5 parts flexible plasticizer, 0.4 parts antioxidant 1010, 0.3 parts ultraviolet absorber UV-327, and 1.8 parts trimethylolpropane triacrylate; the ethylene-vinyl acetate copolymer is ethylene-vinyl acetate copolymer EVA1828, provided by Hanwha Chemical; the low-density polyethylene is grade 2102-TN00; the flexible plasticizer is a compound of dibutyl phthalate and epoxidized soybean oil in a 1:1 mass ratio; the polyester fiber buffer layer is made of 120D polyester fiber braided tape with a thickness of 0.1mm and a wrapping overlap rate of 20%; the stranded tin-plated copper conductor is made of 0.15mm tin-plated copper wire, which meets the requirements of IEC 60228 standard Class 5 soft copper conductor.

[0049] A method for preparing the aforementioned flexible abrasion-resistant cable includes the following steps: Step S1, stranded conductor preparation: 0.15mm tin-plated copper wire is stranded at a pitch ratio of 12:1 to obtain a Class 5 soft copper conductor that conforms to the IEC 60228 standard. After stranding, annealing treatment is performed to improve the conductor's flexibility. Step S2, Insulation Layer Extrusion and Irradiation Crosslinking: Add the insulation layer raw materials to a high-speed mixer according to the formula and stir for 5 minutes. Then, send the mixture to a twin-screw extruder for melt blending. The extrusion temperature range is 130-160℃. Extrude the molten material onto the outside of the conductor. The extrusion thickness is controlled at 0.8 mm. Send the extruded insulated wire core into an electron irradiation device and perform irradiation crosslinking with a dose of 15 kGy to improve the mechanical strength and heat resistance of the insulation layer. Step S3, Buffer layer wrapping: Polyester fiber braided tape is wrapped around the outside of the insulated wire core using a wrapping machine. The wrapping tension is controlled at 10N and the overlap rate is maintained at 20%, which plays a role in buffering bending stress. Step S4, Double-layer sheath extrusion: A dual-extruder synchronous extrusion process is adopted. First, the inner flexible matrix layer is extruded through the first extruder, with the extrusion temperature controlled at 140-170℃ and the extrusion thickness at 1.2mm. After the inner sheath cools down to below 100℃, the outer wear-resistant modified layer is extruded through the second extruder, with the extrusion temperature controlled at 160-190℃ and the extrusion thickness at 0.8mm. The interpenetration of the molten surface layers is used to improve the bonding strength of the two sheaths. Step S5, Steam vulcanization post-treatment: The extruded semi-finished cable is sent into a steam vulcanizing tank and vulcanized at 110℃ and 0.3MPa pressure for 30 minutes to allow the rubber matrix to complete cross-linking and curing, thereby improving the mechanical properties of the sheath layer. Then, it is naturally cooled to room temperature and wound up.

[0050] The annealing temperature in step S1 is 200℃, and the holding time is 1.5h. Example 4

[0051] A flexible wear-resistant cable comprises, from the inside out: stranded tin-plated copper conductor, irradiated cross-linked polyolefin insulation layer, polyester fiber buffer layer, and wear-resistant composite sheath layer; the wear-resistant composite sheath layer is made of the following raw materials in parts by weight: 43 parts of fluorinated silicone thermoplastic polyester elastomer, 24 parts of hydrogenated styrene elastomer SEEPS, 19 parts of vinyl acrylate rubber, 7.5 parts of ultra-high molecular weight polyethylene micro powder, 5.5 parts of nano-silica, 1.8 parts of coupling agent, 3.5 parts of self-lubricating composite agent, 2.3 parts of maleic anhydride graft compatibilizer, 1.6 parts of weathering stabilizer, 0.75 parts of antioxidant, 0.9 parts of lubricant, 0.65 parts of peroxide cross-linking agent, and 0.45 parts of co-cross-linking agent.

[0052] The fluorinated silicone thermoplastic polyester elastomer was prepared according to the method of Example 1 in invention patent document CN109535408B; the hydrogenated styrene elastomer SEEPS was SEPTON. TM 4044SEEPS; the vinyl acrylate rubber is DUPONT Vamac GLS AEM; the ultra-high molecular weight polyethylene micro powder has product number 022 and is provided by Jiangsu Zhongjiang Polymer Co., Ltd.; the average particle size of the nano-silica is 35nm; the coupling agent is a compound of silane coupling agent KH550, silane coupling agent KH560, and silane coupling agent KH570 in a mass ratio of 1:2:1; the self-lubricating composite agent is a compound of silicone powder and fluorinated graphite in a mass ratio of 1:1; the silicone powder is VtecLAP silicone powder. SC001 is provided by Shanghai Fushen New Material Technology Co., Ltd.; the fluorinated graphite is grade FG08, provided by Suzhou Cangmu New Material Co., Ltd.; the maleic anhydride graft compatibilizer is maleic anhydride grafted polyethylene 900E; the weather stabilizer is a mixture of light stabilizer UV-3346 and ultraviolet absorber UV-329 in a mass ratio of 1:1.1; the antioxidant is a mixture of antioxidant 1010 and antioxidant 168 in a mass ratio of 3:5; the lubricant is zinc stearate; the peroxide crosslinking agent is dicumyl peroxide; the co-crosslinking agent is a mixture of bis(1-vinylimidazol-2-)one and tripropylene glycol diacrylate in a mass ratio of 1:2.5.

[0053] The irradiated cross-linked polyolefin insulation layer is made from the following raw materials in parts by weight: 68 parts ethylene-vinyl acetate copolymer, 28 parts low-density polyethylene, 7.5 parts flexible plasticizer, 0.45 parts antioxidant 1010, 0.35 parts ultraviolet absorber UV-327, and 1.9 parts trimethylolpropane triacrylate; the ethylene-vinyl acetate copolymer is ethylene-vinyl acetate copolymer EVA1828, provided by Hanwha Chemical; the low-density polyethylene is grade 2102-TN00; the flexible plasticizer is a compound of dibutyl phthalate and epoxidized soybean oil in a mass ratio of 1:1.1; the polyester fiber buffer layer is made of 120D polyester fiber braided tape with a thickness of 0.1mm and a wrapping overlap rate of 20%; the stranded tin-plated copper conductor is made of 0.15mm tin-plated copper wire, which meets the requirements of IEC 60228 standard Class 5 soft copper conductor.

[0054] A method for preparing the aforementioned flexible abrasion-resistant cable includes the following steps: Step S1, stranded conductor preparation: 0.15mm tin-plated copper wire is stranded at a pitch ratio of 12:1 to obtain a Class 5 soft copper conductor that conforms to the IEC 60228 standard. After stranding, annealing treatment is performed to improve the conductor's flexibility. Step S2, Insulation Layer Extrusion and Irradiation Crosslinking: Add the insulation layer raw materials to a high-speed mixer according to the formula and stir for 5 minutes. Then, send the mixture to a twin-screw extruder for melt blending. The extrusion temperature range is 130-160℃. Extrude the molten material onto the outside of the conductor. The extrusion thickness is controlled at 0.8 mm. Send the extruded insulated wire core into an electron irradiation device and perform irradiation crosslinking with a dose of 15 kGy to improve the mechanical strength and heat resistance of the insulation layer. Step S3, Buffer layer wrapping: Polyester fiber braided tape is wrapped around the outside of the insulated wire core using a wrapping machine. The wrapping tension is controlled at 10N and the overlap rate is maintained at 20%, which plays a role in buffering bending stress. Step S4, Double-layer sheath extrusion: A dual-extruder synchronous extrusion process is adopted. First, the inner flexible matrix layer is extruded through the first extruder, with the extrusion temperature controlled at 140-170℃ and the extrusion thickness at 1.2mm. After the inner sheath cools down to below 100℃, the outer wear-resistant modified layer is extruded through the second extruder, with the extrusion temperature controlled at 160-190℃ and the extrusion thickness at 0.8mm. The interpenetration of the molten surface layers is used to improve the bonding strength of the two sheaths. Step S5, Steam vulcanization post-treatment: The extruded semi-finished cable is sent into a steam vulcanizing tank and vulcanized at 110℃ and 0.3MPa pressure for 30 minutes to allow the rubber matrix to complete cross-linking and curing, thereby improving the mechanical properties of the sheath layer. Then, it is naturally cooled to room temperature and wound up.

[0055] The annealing temperature in step S1 is 210℃, and the holding time is 1.8h. Example 5

[0056] A flexible wear-resistant cable comprises, from the inside out: stranded tin-plated copper conductor, irradiated cross-linked polyolefin insulation layer, polyester fiber buffer layer, and wear-resistant composite sheath layer; the wear-resistant composite sheath layer is made of the following raw materials in parts by weight: 45 parts of fluorinated silicone thermoplastic polyester elastomer, 25 parts of hydrogenated styrene elastomer SEEPS, 20 parts of vinyl acrylate rubber, 8 parts of ultra-high molecular weight polyethylene micro powder, 6 parts of nano silica, 2 parts of coupling agent, 4 parts of self-lubricating composite agent, 2.5 parts of maleic anhydride graft compatibilizer, 1.8 parts of weather stabilizer, 0.8 parts of antioxidant, 1 part of lubricant, 0.7 parts of peroxide cross-linking agent, and 0.5 parts of co-cross-linking agent.

[0057] The fluorinated silicone thermoplastic polyester elastomer was prepared according to the method of Example 1 in invention patent document CN109535408B; the hydrogenated styrene elastomer SEEPS was SEPTON. TM 4044SEEPS; the vinyl acrylate rubber is DUPONT Vamac GLS AEM; the ultra-high molecular weight polyethylene micro powder has product number 022 and is provided by Jiangsu Zhongjiang Polymer Co., Ltd.; the average particle size of the nano-silica is 40nm; the coupling agent is silane coupling agent KH550; the self-lubricating composite agent is a mixture of silicone powder and fluorinated graphite in a 1:1 mass ratio; the silicone powder is VtecLAPSC001 and is provided by Shanghai Fushen New Material Technology Co., Ltd.; the fluorinated graphite is grade FG08 and is provided by Suzhou Cangmu New Material Co., Ltd. The materials are provided by [Company Name]; the maleic anhydride graft compatibilizer is maleic anhydride grafted polyethylene 900E; the weather stabilizer is a mixture of light stabilizer UV-3346 and ultraviolet absorber UV-329 in a mass ratio of 1:1.2; the antioxidant is antioxidant 1010; the lubricant is zinc stearate; the peroxide crosslinking agent is dicumyl peroxide; the co-crosslinking agent is a mixture of bis(1-vinylimidazol-2-)one and tripropylene glycol diacrylate in a mass ratio of 1:3.

[0058] The irradiated cross-linked polyolefin insulation layer is made from the following raw materials in parts by weight: 70 parts ethylene-vinyl acetate copolymer, 30 parts low-density polyethylene, 8 parts flexible plasticizer, 0.5 parts antioxidant 1010, 0.4 parts ultraviolet absorber UV-327, and 2.0 parts trimethylolpropane triacrylate; the ethylene-vinyl acetate copolymer is ethylene-vinyl acetate copolymer EVA1828, provided by Hanwha Chemical; the low-density polyethylene is grade 2102-TN00; the flexible plasticizer is a compound of dibutyl phthalate and epoxidized soybean oil in a mass ratio of 1:1.2; the polyester fiber buffer layer is made of 120D polyester fiber braided tape with a thickness of 0.1mm and a wrapping overlap rate of 20%; the stranded tin-plated copper conductor is made of 0.15mm tin-plated copper wire, which meets the requirements of IEC 60228 standard Class 5 soft copper conductor.

[0059] A method for preparing the aforementioned flexible abrasion-resistant cable includes the following steps: Step S1, stranded conductor preparation: 0.15mm tin-plated copper wire is stranded at a pitch ratio of 12:1 to obtain a Class 5 soft copper conductor that conforms to the IEC 60228 standard. After stranding, annealing treatment is performed to improve the conductor's flexibility. Step S2, Insulation Layer Extrusion and Irradiation Crosslinking: Add the insulation layer raw materials to a high-speed mixer according to the formula and stir for 5 minutes. Then, send the mixture to a twin-screw extruder for melt blending. The extrusion temperature range is 130-160℃. Extrude the molten material onto the outside of the conductor. The extrusion thickness is controlled at 0.8 mm. Send the extruded insulated wire core into an electron irradiation device and perform irradiation crosslinking with a dose of 15 kGy to improve the mechanical strength and heat resistance of the insulation layer. Step S3, Buffer layer wrapping: Polyester fiber braided tape is wrapped around the outside of the insulated wire core using a wrapping machine. The wrapping tension is controlled at 10N and the overlap rate is maintained at 20%, which plays a role in buffering bending stress. Step S4, Double-layer sheath extrusion: A dual-extruder synchronous extrusion process is adopted. First, the inner flexible matrix layer is extruded through the first extruder, with the extrusion temperature controlled at 140-170℃ and the extrusion thickness at 1.2mm. After the inner sheath cools down to below 100℃, the outer wear-resistant modified layer is extruded through the second extruder, with the extrusion temperature controlled at 160-190℃ and the extrusion thickness at 0.8mm. The interpenetration of the molten surface layers is used to improve the bonding strength of the two sheaths. Step S5, Steam vulcanization post-treatment: The extruded semi-finished cable is sent into a steam vulcanizing tank and vulcanized at 110℃ and 0.3MPa pressure for 30 minutes to allow the rubber matrix to complete cross-linking and curing, thereby improving the mechanical properties of the sheath layer. Then, it is naturally cooled to room temperature and wound up.

[0060] The annealing temperature in step S1 is 220℃, and the holding time is 2h.

[0061] Comparative Example 1 This example provides a flexible wear-resistant cable and its preparation method, which is basically the same as that in Example 5, except that an equal amount of fluorinated silicone thermoplastic polyester elastomer is used instead of hydrogenated styrene elastomer SEEPS.

[0062] Comparative Example 2 This example provides a flexible wear-resistant cable and its preparation method, which is basically the same as that in Example 5, except that an equal amount of fluorinated silicone thermoplastic polyester elastomer is used instead of vinyl acrylate rubber.

[0063] Comparative Example 3 This example provides a flexible wear-resistant cable and its preparation method, which is basically the same as that in Example 5, except that an equal amount of hydrogenated styrene elastomer SEEPS is used instead of vinyl acrylate rubber.

[0064] Comparative Example 4 This example provides a flexible wear-resistant cable and its preparation method, which is basically the same as that in Example 5, except that an equal amount of vinyl acrylate rubber is used instead of hydrogenated styrene elastomer SEEPS.

[0065] Comparative Example 5 This example provides a flexible wear-resistant cable and its preparation method, which is basically the same as that in Example 5, except that an equal amount of bis(1-vinylimidazol-2-)one is used instead of tripropylene glycol diacrylate.

[0066] Comparative Example 6 This example provides a flexible wear-resistant cable and its preparation method, which is basically the same as that in Example 5, except that an equal amount of tripropylene glycol diacrylate is used instead of bis(1-vinylimidazol-2-)one.

[0067] The cable samples from Example 5 and Comparative Examples 1-6 were subjected to performance testing according to the following experimental methods. All experiments were conducted under standard environmental conditions (temperature 23±2℃, humidity 50±5%RH), referring to national standards and specific experimental methods as follows: 1. Flexibility test (minimum bending radius): Refer to GB / T 5013.2-2008 "Rubber insulated cables with rated voltage of 450 / 750V and below - Part 2: Test methods", bend the cable sample with different bending radii, observe whether the cable has sheath cracking, insulation layer damage, conductor wire breakage, etc., and record the minimum bending radius (expressed as a multiple of the cable outer diameter D).

[0068] 2. Abrasion resistance test: The abrasion resistance of the cable sample was determined with reference to GB / T 17737.324-2018 "Coaxial Communication Cables - Part 1-324: Mechanical Test Methods - Cable Abrasion Resistance Test".

[0069] 3. Structural stability test: After the cable sample is subjected to 1 million bending fatigue tests, the cable is dissected and the delamination, peeling, displacement and other phenomena are observed between each layer (stranded tin-plated copper conductor, irradiated cross-linked polyolefin insulation layer, polyester fiber buffer layer, wear-resistant composite sheath layer). The structural stability level is recorded (excellent: no delamination, no peeling, no displacement; qualified: slight delamination, no peeling, no displacement; unqualified: obvious delamination, peeling or displacement).

[0070] 4. Torsion Resistance: The torsion resistance of the cable samples was determined according to standard GB / T 29631-2013 "Torsion-resistant Flexible Cables for Wind Power Generation with Rated Voltage of 1.8 / 3 kV and Below". The samples were subjected to 10,000 cycles of torsion at room temperature, and the cracking was observed. The test results are shown in Table 1.

[0071] Table 1. Performance test results of flexible abrasion-resistant cables As can be seen from the data in Table 1, the flexible abrasion-resistant cable of Example 5 has the best overall performance. Its minimum bending radius (4D), abrasion resistance (18,500 times), and structural stability after 1 million bending cycles are excellent, and it is resistant to torsion without cracking. In the comparative examples, due to the replacement of key components (elastomer or co-crosslinking agent), the performance of each component deteriorated to varying degrees. This fully demonstrates that fluorosilicone thermoplastic polyester elastomer, vinyl acrylate rubber, hydrogenated styrene elastomer SEEPS, tripropylene glycol diacrylate, and bis(1-vinylimidazol-2-)one play a key role in improving the performance of the flexible abrasion-resistant cable, and none of them can be omitted.

[0072] The above embodiments are only for illustrating the technical concept and features of the present invention. Their purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be used to limit the scope of protection of the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A flexible, wear-resistant cable, characterized in that, From the inside out, it comprises: stranded tin-plated copper conductor, irradiated cross-linked polyolefin insulation layer, polyester fiber buffer layer, and wear-resistant composite sheath layer; the wear-resistant composite sheath layer is made of the following raw materials in parts by weight: 35-45 parts of fluorinated silicone thermoplastic polyester elastomer, 20-25 parts of hydrogenated styrene elastomer SEEPS, 15-20 parts of vinyl acrylate rubber, 5-8 parts of ultra-high molecular weight polyethylene micro powder, 3-6 parts of nano silica, 1-2 parts of coupling agent, 2-4 parts of self-lubricating composite agent, 1.5-2.5 parts of maleic anhydride graft compatibilizer, 1.0-1.8 parts of weather stabilizer, 0.4-0.8 parts of antioxidant, 0.5-1 part of lubricant, 0.4-0.7 parts of peroxide cross-linking agent, and 0.3-0.5 parts of co-cross-linking agent.

2. The flexible wear-resistant cable according to claim 1, characterized in that, The hydrogenated styrene elastomer SEEPS is SEPTONTM 4044SEEPS; the vinyl acrylate rubber is DUPONT Vamac GLS AEM; and the product number of the ultra-high molecular weight polyethylene micro powder is 022.

3. The flexible wear-resistant cable according to claim 1, characterized in that, The average particle size of the nano-silica is 20-40 nm; the coupling agent is at least one of silane coupling agent KH550, silane coupling agent KH560, and silane coupling agent KH570.

4. The flexible wear-resistant cable according to claim 1, characterized in that, The self-lubricating composite agent is a mixture of silicone powder and fluorinated graphite in a 1:1 mass ratio; the silicone powder is VtecLAP SC001; and the fluorinated graphite is of grade FG08.

5. The flexible wear-resistant cable according to claim 1, characterized in that, The maleic anhydride graft compatibilizer is maleic anhydride-grafted polyethylene 900E; the weather stabilizer is a mixture of light stabilizer UV-3346 and ultraviolet absorber UV-329 in a mass ratio of 1:(0.8-1.2); the antioxidant is at least one of antioxidant 1010 and antioxidant 168; the lubricant is zinc stearate; the peroxide crosslinking agent is dicumyl peroxide; and the co-crosslinking agent is a mixture of bis(1-vinylimidazol-2-)one and tripropylene glycol diacrylate in a mass ratio of 1:(1-3).

6. The flexible wear-resistant cable according to claim 1, characterized in that, The irradiated cross-linked polyolefin insulating layer is made from the following raw materials in parts by weight: 60-70 parts of ethylene-vinyl acetate copolymer, 20-30 parts of low-density polyethylene, 5-8 parts of flexible plasticizer, 0.3-0.5 parts of antioxidant 1010, 0.2-0.4 parts of ultraviolet absorber UV-327, and 1.5-2.0 parts of trimethylolpropane triacrylate.

7. The flexible wear-resistant cable according to claim 6, characterized in that, The ethylene-vinyl acetate copolymer is ethylene-vinyl acetate copolymer EVA1828; the low-density polyethylene is grade 2102-TN00; the flexible plasticizer is a compound of dibutyl phthalate and epoxidized soybean oil in a mass ratio of 1:(0.8-1.2).

8. The flexible wear-resistant cable according to claim 1, characterized in that, The polyester fiber buffer layer is made of 120D polyester fiber braided tape with a thickness of 0.1mm and a wrapping overlap rate of 20%; the stranded tinned copper conductor is made of 0.15mm tinned copper wire, which meets the requirements of Category 5 soft copper conductors in IEC 60228 standard.

9. A method for preparing a flexible wear-resistant cable according to any one of claims 1-8, characterized in that, Includes the following steps: Step S1, stranded conductor preparation: 0.15mm tin-plated copper wire is stranded at a pitch ratio of 12:1 to obtain a Class 5 soft copper conductor that conforms to the IEC 60228 standard. After stranding, annealing treatment is performed to improve the conductor's flexibility. Step S2, Insulation Layer Extrusion and Irradiation Crosslinking: Add the insulation layer raw materials to a high-speed mixer according to the formula and stir for 5 minutes. Then, send the mixture to a twin-screw extruder for melt blending. The extrusion temperature range is 130-160℃. Extrude the molten material onto the outside of the conductor. The extrusion thickness is controlled at 0.8 mm. Send the extruded insulated wire core into an electron irradiation device and perform irradiation crosslinking with a dose of 15 kGy to improve the mechanical strength and heat resistance of the insulation layer. Step S3, Buffer layer wrapping: Polyester fiber braided tape is wrapped around the outside of the insulated wire core using a wrapping machine. The wrapping tension is controlled at 10N and the overlap rate is maintained at 20%, which plays a role in buffering bending stress. Step S4, Double-layer sheath extrusion: A dual-extruder synchronous extrusion process is adopted. First, the inner flexible matrix layer is extruded through the first extruder, with the extrusion temperature controlled at 140-170℃ and the extrusion thickness at 1.2mm. After the inner sheath cools down to below 100℃, the outer wear-resistant modified layer is extruded through the second extruder, with the extrusion temperature controlled at 160-190℃ and the extrusion thickness at 0.8mm. The interpenetration of the molten surface layers is used to improve the bonding strength of the two sheaths. Step S5, Steam vulcanization post-treatment: The extruded semi-finished cable is sent into a steam vulcanizing tank and vulcanized at 110℃ and 0.3MPa pressure for 30 minutes to allow the rubber matrix to complete cross-linking and curing, thereby improving the mechanical properties of the sheath layer. Then, it is naturally cooled to room temperature and wound up.

10. The method for preparing the flexible wear-resistant cable according to claim 9, characterized in that, The annealing temperature in step S1 is 180-220℃, and the holding time is 1-2 hours.

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