High strength weather resistant drum flat cable
By using multi-strand stranded copper conductors, inner insulation layers, and weather-resistant outer sheath layers in flat tubular cables, especially the self-made weather-resistant additives for the outer sheath layers, the problem of insufficient mechanical strength and weather resistance of polyvinyl chloride materials was solved, and the performance of high-strength and weather-resistant cables was improved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- JIANGXI XINJI CABLE CO LTD
- Filing Date
- 2026-04-30
- Publication Date
- 2026-06-23
AI Technical Summary
Existing flat cables made of polyvinyl chloride (PVC) material are insufficient in terms of mechanical strength and weather resistance, making it difficult to meet the needs of frequent winding and use in complex environments. They are prone to problems such as sheath cracking, insulation damage, and thermal breakdown.
It adopts a multi-strand stranded copper conductor, an inner insulation layer and a weather-resistant outer sheath layer. The inner insulation layer is composed of PVC resin, trioctyl trimellitate, etc., and the outer sheath layer is made of calcined kaolin and self-made weather-resistant additives. The latter is synthesized through a three-step reaction and contains triazine, thiophene and benzophenone groups to enhance weather resistance and thermal stability.
It significantly improves the mechanical strength and weather resistance of the cable, avoids sheath cracking, insulation damage and thermal breakdown, and extends service life.
Smart Images
Figure REF-OBJ-1777518887195-000001 
Figure REF-OBJ-1777518887195-000002
Abstract
Description
Technical Field
[0001] This invention belongs to the field of reel flat cable technology, specifically, it relates to a high-strength weather-resistant reel flat cable. Background Technology
[0002] As a special type of cable, flat cable is widely used in mobile power devices that require frequent dragging and winding, such as cranes, conveyors, elevators, and mining equipment, due to its flat structure, which makes it easy to wind, flexible in laying, and occupies little space. It is also widely used in building power distribution, urban low-voltage power distribution networks, and industrial automation control, undertaking important functions such as power connection, control signal transmission, and lighting power supply. Its performance is directly related to the stable operation of related equipment and the safety of people and property.
[0003] Currently, most flat cables on the market use polyvinyl chloride (PVC) as the main cable material, including both the insulation layer and the outer sheath. This is primarily because PVC has a wide availability of raw materials, mature processing technology, and low production costs. It also possesses certain electrical insulation properties and mechanical strength, meeting basic usage requirements in ordinary scenarios, and has been widely adopted in the field of medium and low voltage cables. However, with the expansion of industrial production scale and the increasing complexity of application environments, existing flat cables using PVC cable materials are gradually revealing many performance defects, making them unsuitable for demanding usage scenarios.
[0004] First, the mechanical strength of PVC cable materials is insufficient, making it difficult to meet the demands of frequent winding and dragging of flat cables. Flat cables in practical applications undergo repeated bending, stretching, and compression, especially when used on large machinery such as cranes and mining equipment. The cables need to be constantly wound and unwound as the equipment operates, bearing long-term cyclic mechanical stress. Traditional PVC materials have low tensile strength and elongation at break, and poor fatigue resistance. Under long-term mechanical action, they are prone to sheath cracking and insulation damage, leading to exposed conductors and potential short circuits, leakage, and other safety hazards, severely impacting cable lifespan and safety. Second, PVC cable materials have poor weather resistance and are prone to aging failure in complex environments. Flat cables are often used in diverse scenarios, with many cables requiring long-term use in harsh environments such as outdoors, high temperature, high humidity, and strong ultraviolet radiation. PVC materials lack thermal stability, with a long-term operating temperature typically not exceeding 70℃. In high-temperature environments or when the cable is overloaded, it is prone to softening, deformation, and even thermal breakdown.
[0005] In summary, there is an urgent need to invent a flat cable with both high strength and weather resistance to meet the higher technical requirements in the field of flat cable technology. Summary of the Invention
[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a high-strength, weather-resistant reel flat cable.
[0007] The objective of this invention can be achieved through the following technical solutions: A high-strength, weather-resistant flat reel cable includes a multi-strand stranded copper conductor, an inner insulation layer, a filler reinforcement layer, and a weather-resistant outer sheath layer.
[0008] Preferably, the material of the inner insulation layer comprises the following raw materials in parts by weight: 80-100 parts PVC resin, 30-40 parts trioctyl trimellitate, 10-15 parts nano calcium carbonate, 5-8 parts antimony trioxide, 1-2 parts antioxidant and 0.5-1 part lubricant.
[0009] Preferably, the material of the filling reinforcement layer is glass fiber rope.
[0010] Preferably, the material of the weather-resistant outer sheath layer comprises the following raw materials in parts by weight: 80-100 parts PVC resin, 20-30 parts dioctyl sebacate, 10-20 parts calcined kaolin, 8-12 parts inorganic flame retardant, 3-5 parts organotin stabilizer, 4-8 parts weather-resistant additives, and 1-2 parts lubricant.
[0011] Preferably, the antioxidant is a phenolic antioxidant.
[0012] Preferably, the lubricant is polyethylene wax, calcium stearate, and zinc stearate.
[0013] Preferably, the weather-resistant additive is prepared through the above steps: Step 1: Add magnesium shavings, anhydrous solvent and iodine granules to a dry three-necked flask. Under nitrogen protection, dissolve 2-bromothiophene in the anhydrous solvent and add it dropwise to the flask. After the addition is complete, heat to 58-60℃ and stir the reaction for 1-2 hours until the magnesium shavings are basically gone. The reaction is complete, and a solution containing thiophene-based magnesium bromide is obtained. Step 2: Add cyanuric chloride and anhydrous solvent to a dry three-necked flask, and then slowly add the solution containing thiophene magnesium bromide prepared in Step 1 to the flask. After the addition is complete, heat to 58-60℃ and stir the reaction for 5-6 hours. After the reaction is complete, the intermediate product is obtained after post-processing. Step 3: Add 2,4-dihydroxybenzophenone and anhydrous solvent to a dry three-necked flask, then add alkali, and stir at room temperature for 30-60 minutes to form a phenolic anion at the 4-position of 2,4-dihydroxybenzophenone. Then add the intermediate product prepared in Step 2, heat to 80-100℃, and stir for 5-6 hours. After the reaction is complete, the weather-resistant additive is obtained after post-treatment.
[0014] Preferably, the molar ratio of the magnesium shavings, 2-bromothiophene, cyanuric chloride, 2,4-dihydroxybenzophenone and the alkali is 2.1-2.2:2:1:1:1.
[0015] Preferably, the anhydrous solvent in steps one and two is anhydrous tetrahydrofuran.
[0016] Preferably, the anhydrous solvent in step three is anhydrous N,N-dimethylformamide.
[0017] Preferably, the alkali in step three is anhydrous potassium carbonate.
[0018] The reaction formula for preparing the weather-resistant additive is as follows: This invention prepares a weather-resistant additive through a three-step reaction. As can be seen from the above reaction formula, the prepared additive molecule contains triazine, thiophene, and benzophenone groups. The triazine structure provides efficient bulk ultraviolet absorption and effectively disperses the excited-state energy generated after light absorption. The introduction of the thiophene ring expands the conjugated system and broadens the spectral absorption range. The benzophenone unit supplements the absorption in the short-wave ultraviolet region and can safely dissipate energy through an intramolecular hydrogen transfer mechanism. The three groups work synergistically, not only achieving complementary absorption spectra but also significantly reducing the risk of photofatigue in a single structure, improving weather resistance, and extending the material's service life. Finally, the additive molecule contains multiple benzene rings, and the thiophene is a rigid, thermally stable aromatic heterocyclic structure, which also provides thermal stability to the matrix at high temperatures.
[0019] The beneficial effects of this invention are: 1. This invention significantly enhances the strength of the cable by using multi-strand stranded copper conductors and a filling reinforcement layer, and by adding calcined kaolin to the outer sheath layer, making it suitable for harsh mechanical operating environments. 2. A self-made weather-resistant additive is added to the outer sheath layer. This additive can broaden the ultraviolet absorption range, synergistically dissipate light energy, and reduce the risk of light fatigue, thereby significantly improving the weather resistance of the cable. 3. The rigid aromatic heterocyclic structure in the weather-resistant additives improves the thermal stability of the cable material at high temperatures, avoiding the problems of softening, deformation or thermal breakdown of traditional PVC materials; In summary, the cable produced by this invention has both high strength and weather resistance, and has important application value in the field of reel flat cable technology. Detailed Implementation
[0020] The technical solutions in the embodiments of the present invention will be clearly and completely described below. 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 skilled in the art without creative effort are within the scope of protection of the present invention.
[0021] Example 1 Preparation of weather-resistant additives: Step 1: Add 2.6g of magnesium shavings, 10mL of anhydrous tetrahydrofuran and one iodine granule to a dry three-necked flask. Under nitrogen protection, dissolve 16.3g of 2-bromothiophene in 40mL of anhydrous tetrahydrofuran and then add it dropwise to the flask. After the addition is complete, heat to 60℃ and stir the reaction for 2 hours until the magnesium shavings are basically gone. The reaction is complete, and a solution containing thiophene-based magnesium bromide is obtained. Step 2: Add 9.2g of cyanuric chloride and anhydrous tetrahydrofuran to a dry three-necked flask. Then, slowly add the solution containing thiophene magnesium bromide prepared in Step 1 to the flask. After the addition is complete, heat to 60℃ and stir for 6 hours. When the reaction is complete, quench with saturated ammonium chloride solution, extract with ethyl acetate, wash the organic phase with water, dry (anhydrous sodium sulfate), filter, concentrate by rotary evaporation, and separate by column chromatography to obtain the intermediate product. Step 3: Add 10.7g of 2,4-dihydroxybenzophenone and anhydrous N,N-dimethylformamide to a dry three-necked flask, then add 6.9g of anhydrous potassium carbonate. Stir at room temperature for 30min to form a phenolic anion at the 4-position of 2,4-dihydroxybenzophenone. Then add the intermediate product prepared in Step 2, heat to 80℃, stir and react for 5h. After the reaction is complete, cool, add distilled water, extract with dichloromethane, wash the organic phase with water until neutral, dry (anhydrous sodium sulfate), filter, concentrate by rotary evaporation, and separate by column chromatography to obtain the weather-resistant additive. Manufacturing high-strength weather-resistant cylindrical flat cables: S1. Using 0.15mm annealed copper wire as the conductor single wire, multiple bundles of single wires are twisted together in a regular twisting method, with the twisting pitch being 10 times the twisting diameter, to obtain a multi-strand twisted copper conductor. S2. The following materials for the inner insulation layer are mixed: 80 parts PVC resin, 30 parts trioctyl trimellitate, 10 parts nano calcium carbonate, 5 parts antimony trioxide, 1 part antioxidant 1010 and 0.5 parts polyethylene wax. The mixture is then fed into a twin-screw extruder to extrude and coat the surface of the copper conductor to form an inner insulation layer. The thickness of the insulation layer is controlled to be 0.8 mm. After extrusion, the insulation is cooled by water to obtain the insulated wire core. S3. Arrange multiple insulated wire cores according to the flat structure requirements of a tube flat cable. Fill the gaps between the insulated wire cores with fiberglass rope, ensuring tight filling without gaps during the filling process to prevent the insulated wire cores from shifting when the cable is bent. Then, send the filled insulated wire cores into a cabling machine for cabling processing to prepare the cabled wire cores. S4. Finally, the materials for the weather-resistant outer sheath layer—80 parts PVC resin, 20 parts dioctyl sebacate, 10 parts calcined kaolin, 8 parts zinc borate, 3 parts organotin stabilizer, 4 parts weather-resistant additives, and 1 part polyethylene wax—are mixed and fed into a twin-screw extruder to be extruded and coated onto the surface of the cable core to form the outer sheath layer. The thickness of the outer sheath is controlled to be 1.5 mm. After extrusion, water cooling is used to ensure the outer sheath is shaped, resulting in a high-strength weather-resistant flat cable.
[0022] Example 2 The only difference between this embodiment and Embodiment 1 is that, in this embodiment, a high-strength weather-resistant reel flat cable is obtained through the following steps: S1. Using 0.15mm annealed copper wire as the conductor single wire, multiple bundles of single wires are twisted together in a regular twisting method, with the twisting pitch being 10 times the twisting diameter, to obtain a multi-strand twisted copper conductor. S2. The following materials for the inner insulation layer are mixed: 90 parts PVC resin, 35 parts trioctyl trimellitate, 12.5 parts nano calcium carbonate, 6.5 parts antimony trioxide, 1.5 parts antioxidant 1010 and 1 part calcium stearate. The mixture is then fed into a twin-screw extruder to extrude and coat the surface of the copper conductor to form an inner insulation layer. The thickness of the insulation layer is controlled to be 0.8 mm. After extrusion, the insulation is cooled by water to obtain the insulated wire core. S3. Arrange multiple insulated wire cores according to the flat structure requirements of a tube flat cable. Fill the gaps between the insulated wire cores with fiberglass rope, ensuring tight filling without gaps during the filling process to prevent the insulated wire cores from shifting when the cable is bent. Then, send the filled insulated wire cores into a cabling machine for cabling processing to prepare the cabled wire cores. S4. Finally, the materials for the weather-resistant outer sheath layer—90 parts PVC resin, 25 parts dioctyl sebacate, 15 parts calcined kaolin, 10 parts zinc borate, 4 parts organotin stabilizer, 6 parts weather-resistant additives, and 1.5 parts calcium stearate—are mixed and fed into a twin-screw extruder to be extruded and coated onto the surface of the cable core to form the outer sheath layer. The thickness of the outer sheath is controlled to be 1.5 mm. After extrusion, water cooling is used to ensure the outer sheath is shaped, resulting in a high-strength weather-resistant flat cable.
[0023] Example 3 The only difference between this embodiment and Embodiment 1 is that, in this embodiment, a high-strength weather-resistant reel flat cable is obtained through the following steps: S1. Using 0.15mm annealed copper wire as the conductor single wire, multiple bundles of single wires are twisted together in a regular twisting method, with the twisting pitch being 10 times the twisting diameter, to obtain a multi-strand twisted copper conductor. S2. The following materials for the inner insulation layer are mixed: 100 parts PVC resin, 40 parts trioctyl trimellitate, 15 parts nano calcium carbonate, 8 parts antimony trioxide, 2 parts antioxidant 1010 and 1 part zinc stearate. The mixture is then fed into a twin-screw extruder to extrude and coat the surface of the copper conductor to form an inner insulation layer. The thickness of the insulation layer is controlled to be 0.8 mm. After extrusion, the insulation is cooled by water to obtain the insulated wire core. S3. Arrange multiple insulated wire cores according to the flat structure requirements of a tube flat cable. Fill the gaps between the insulated wire cores with fiberglass rope, ensuring tight filling without gaps during the filling process to prevent the insulated wire cores from shifting when the cable is bent. Then, send the filled insulated wire cores into a cabling machine for cabling processing to prepare the cabled wire cores. S4. Finally, the materials for the weather-resistant outer sheath layer—100 parts PVC resin, 30 parts dioctyl sebacate, 20 parts calcined kaolin, 12 parts zinc borate, 5 parts organotin stabilizer, 8 parts weather-resistant additives, and 2 parts zinc stearate—are mixed and fed into a twin-screw extruder to be extruded and coated onto the surface of the cable core to form the outer sheath layer. The thickness of the outer sheath is controlled to be 1.5 mm. After extrusion, water cooling is used to ensure the outer sheath is shaped, resulting in a high-strength weather-resistant flat cable.
[0024] Comparative Example 1 The difference between this comparative example and Example 3 is that no weather-resistant additives were added in this comparative example to obtain the cable.
[0025] Comparative Example 2 The difference between this comparative example and Example 3 is that in this comparative example, calcined kaolin is not added to obtain the cable.
[0026] The outer sheath materials obtained in Examples 1, 2, and 3, and Comparative Examples 1 and 2 were extruded separately and subjected to the following performance tests: The tensile strength of the specimens was determined according to GB / T 1040 standard. The mass loss of the sample after aging at 100±2℃ for 168h was determined according to GB / T 8815 standard. The surface condition of the samples after 500 hours of UV aging was determined using the GB / T 16422 standard. The measurement results are shown in Table 1: Table 1 As can be seen from the test results in Table 1, the outer sheath material prepared in the embodiment of the present invention has higher strength, heat resistance and UV resistance than the comparative example. Therefore, the cable made using this outer sheath material also has high strength and weather resistance, and has important application value in the field of roll flat cable technology.
[0027] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.
Claims
1. A high-strength, weather-resistant flat reel cable, comprising multi-strand stranded copper conductors, an inner insulation layer, a filler reinforcement layer, and a weather-resistant outer sheath layer, characterized in that, The material of the weather-resistant outer sheath layer includes the following raw materials in parts by weight: 80-100 parts PVC resin, 20-30 parts dioctyl sebacate, 10-20 parts calcined kaolin, 8-12 parts inorganic flame retardant, 3-5 parts organotin stabilizer, 4-8 parts weather-resistant additives, and 1-2 parts lubricant.
2. The high-strength weather-resistant reel flat cable according to claim 1, characterized in that, The material of the inner insulation layer includes the following raw materials in parts by weight: 80-100 parts PVC resin, 30-40 parts trioctyl trimellitate, 10-15 parts nano calcium carbonate, 5-8 parts antimony trioxide, 1-2 parts antioxidant and 0.5-1 part lubricant.
3. The high-strength weather-resistant reel flat cable according to claim 1, characterized in that, The material of the filling reinforcement layer is fiberglass rope.
4. A high-strength weather-resistant reel flat cable according to claim 1, characterized in that, The weather-resistant additive is prepared through the above steps: Step 1: Add magnesium shavings, anhydrous solvent and iodine granules to a flask. Under nitrogen protection, dissolve 2-bromothiophene in anhydrous solvent and add it dropwise to the flask. After the addition is complete, heat to 58-60℃ and stir the reaction for 1-2 hours. Once the reaction is complete, a solution containing thiophene-based magnesium bromide is obtained. Step 2: Add cyanuric chloride and anhydrous solvent to the flask, and then slowly add the solution of magnesium bromide containing thiophene group prepared in Step 1 to the flask. After the addition is complete, heat to 58-60℃ and stir the reaction for 5-6 hours. The reaction is complete, and the intermediate product is obtained. Step 3: Add 2,4-dihydroxybenzophenone and anhydrous solvent to the flask, then add alkali, stir at room temperature for 30-60 min, then add the intermediate product prepared in step 2, heat to 80-100℃, stir and react for 5-6 h, the reaction is complete, and the weather-resistant additive is obtained.
5. A high-strength weather-resistant reel flat cable according to claim 4, characterized in that, The molar ratio of the magnesium shavings, 2-bromothiophene, cyanuric chloride, 2,4-dihydroxybenzophenone and the alkali is 2.1-2.2:2:1:1:
1.
6. A high-strength weather-resistant reel flat cable according to claim 4, characterized in that, The anhydrous solvent in steps one and two is anhydrous tetrahydrofuran.
7. A high-strength weather-resistant reel flat cable according to claim 4, characterized in that, The anhydrous solvent in step three is anhydrous N,N-dimethylformamide.
8. A high-strength weather-resistant reel flat cable according to claim 4, characterized in that, In step three, the alkali is anhydrous potassium carbonate.
9. A high-strength weather-resistant reel flat cable according to claim 1, characterized in that, The antioxidant is a phenolic antioxidant.
10. A high-strength, weather-resistant reel flat cable according to claim 1, characterized in that, The lubricant is polyethylene wax, calcium stearate, and zinc stearate.