Submarine cable composite conductor, its manufacturing method and production equipment

Abstract

A submarine cable composite conductor, its manufacturing method and production equipment. Among them, the manufacturing method of the submarine cable composite conductor is provided with a conductive layer, a water-blocking layer, a binding layer and a protective layer from the inside to the outside in sequence. The conductive layer includes a plurality of stranded composite conductor filaments, and the composite conductor filaments include an aluminum core body and a copper cladding layer to reduce the conductor cost. The water-blocking layer includes a semiconductive water-blocking glue and a water-blocking tape. The water-blocking tape is coated on the surface of the conductive layer, and the semiconductive water-blocking glue is filled between the conductive layer and the water-blocking tape and between a plurality of composite conductor filaments to improve the water-blocking performance. The semiconductive water-blocking glue includes a first component and a second component mixed in equal proportion. The first component includes 60-80 parts of an inorganic modified resin, 10-15 parts of an active fluorocarbon resin, 10-15 parts of a polyethylene waterproofing agent, 30-40 parts of conductive carbon black, 3-5 parts of a stabilizer, and 2-3 parts of a coupling agent; the second component includes 80-90 parts of silicone oil and 10-15 parts of an expanding powder.

Description

Technical Field

[0001] This application relates to the technical field of submarine cables, and more particularly, to a composite conductor for submarine cables, a manufacturing method thereof, and production equipment. Background Art

[0002] Since submarine cables are installed on the seabed with a complex environment, their design, manufacturing, and installation requirements are much higher than those of ordinary cables. Existing submarine cables mostly adopt copper conductor structures, resulting in relatively high manufacturing, transportation, and laying costs. However, with the development of submarine cable technology, marine activities will move towards the deeper and more resource-rich open sea. As the core part of submarine cables, the water-blocking effect of the water-blocking conductor largely determines the service life of submarine cables. How to reduce the cost of the submarine cable conductor and improve the water-blocking performance of the submarine cable conductor has become a technical problem that urgently needs to be solved. Summary of the Invention

[0003] This application provides a composite conductor for submarine cables, a manufacturing method thereof, and production equipment to solve the above technical problems.

[0004] The embodiments of this application are implemented as follows:

[0005] A composite conductor for submarine cables includes a conductive layer, a water-blocking layer, and a binding layer arranged in sequence from the inside to the outside;

[0006] The conductive layer includes a plurality of composite conductor filaments stranded together. Each composite conductor filament includes an aluminum core and a copper cladding layer, and the copper cladding layer is arranged on the surface of the aluminum core;

[0007] The water-blocking layer includes a semi-conductive water-blocking glue and a water-blocking tape. The water-blocking tape is coated on the surface of the conductive layer, and the semi-conductive water-blocking glue is filled between the conductive layer and the water-blocking tape and between a plurality of the composite conductor filaments; the semi-conductive water-blocking glue includes a first component and a second component mixed in equal proportion. The first component includes 60 - 80 parts of an inorganic modified resin, 10 - 15 parts of an active fluorocarbon resin, 10 - 15 parts of a polyethylene waterproofing agent, 30 - 40 parts of conductive carbon black, 3 - 5 parts of a stabilizer, and 2 - 3 parts of a coupling agent; the second component includes 80 - 90 parts of silicone oil and 10 - 15 parts of an expanding powder;

[0008] The material of the binding layer includes a polyester fabric, a semi-conductive adhesive, and a water-absorbing resin;

[0009] The composite conductor for submarine cables further includes a protective layer, and the protective layer is wrapped around the surface of the binding layer.

[0010] In a possible implementation manner: a plurality of the composite conductor filaments are stranded to form multiple layers of the conductive layer, and the stranding directions of adjacent conductive layers are opposite.

[0011] In a possible implementation: the stranding pitch ratio of the multiple conductive layers decreases layer by layer from the inside to the outside.

[0012] In a possible implementation: in each composite conductor single wire, the mass fraction of the copper cladding is 18% - 21%.

[0013] The embodiment of the present application also provides a method for manufacturing a composite conductor of a submarine cable, which is used to prepare the composite conductor of the submarine cable described in the above embodiment, and it includes:

[0014] A composite conductor wire blank is made by cladding an aluminum rod with a copper layer. In the composite conductor wire blank, the mass fraction of the copper layer is 18% - 21%. The composite conductor wire blank is drawn to obtain composite conductor single wires. The composite conductor single wires include an aluminum core and a copper cladding, and the copper cladding is arranged on the surface of the aluminum core;

[0015] Apply a semiconductive water-resistant glue to the surface of the composite conductor single wires; the semiconductive water-resistant glue includes a first component and a second component mixed in equal proportions. The first component includes 60 - 80 parts of an inorganic modified resin, 10 - 15 parts of an active fluorocarbon resin, 10 - 15 parts of a polyethylene waterproofing agent, 30 - 40 parts of conductive carbon black, 3 - 5 parts of a stabilizer, and 2 - 3 parts of a coupling agent; the second component includes 80 - 90 parts of an organic silicone oil and 10 - 15 parts of an expanding powder;

[0016] Strand multiple composite conductor single wires coated with the semiconductive water-resistant glue to form multiple conductive layers, and the stranding directions of adjacent conductive layers are opposite;

[0017] Wrap a water-blocking tape and a binding layer around the surface of the conductive layer. The binding layer is located outside the water-blocking tape. The material of the binding layer includes a polyester fabric, a semiconductive adhesive, and a water-absorbing resin;

[0018] Wrap a protective tape around the surface of the binding layer to form a composite conductor of a submarine cable.

[0019] In a possible implementation: it further includes:

[0020] Dry the composite conductor of the submarine cable to cure and form the semiconductive water-resistant glue; the drying temperature is 30°C - 40°C, and the drying time is 1 - 2 h.

[0021] In a possible implementation: the stranding pitch ratio of the multiple conductive layers decreases layer by layer from the inside to the outside.

[0022] In a possible implementation: the stranding pitch ratio of the innermost conductive layer is less than or equal to 26, and the stranding pitch ratio of the outermost conductive layer is less than or equal to 14.

[0023] In a possible implementation manner: the preparation steps of the first component in the semiconductive water-resistant glue include: uniformly stirring 60-80 parts of inorganic modified resin, 10-15 parts of active fluorocarbon resin, and 10-15 parts of polyethylene waterproofing agent in a constant temperature environment of 100 °C at a speed of 400-600 revolutions per minute. After cooling to room temperature, 30-40 parts of carbon black, 3-5 parts of stabilizer, and 2-3 parts of coupling agent are added, and in a vacuum environment, continuous stirring is carried out at a speed of 1000-1200 revolutions per minute for 2-3 h.

[0024] The embodiment of the present application further provides a production device for a submarine cable composite conductor, which is used to prepare the submarine cable composite conductor described in the above embodiment. The production device for the submarine cable composite conductor includes a stranding body, a wire distributing plate, a glue injection mold, a stranding die, a mold base, an elastic glue removing mechanism, a first wrapping device, a second wrapping device, and a third wrapping device arranged in sequence along the pulling direction of the conductor; the stranding body, the wire distributing plate, and the stranding die are used to strand multiple composite conductor filaments to form a conductive layer; the glue injection mold is arranged between the wire distributing plate and the stranding die and is used to coat semiconductive water-resistant glue on the surface of the composite conductor filaments before the composite conductor filaments are stranded; the semiconductive water-resistant glue includes a first component and a second component mixed in equal proportions. The first component includes 60-80 parts of inorganic modified resin, 10-15 parts of active fluorocarbon resin, 10-15 parts of polyethylene waterproofing agent, 30-40 parts of conductive carbon black, 3-5 parts of stabilizer, and 2-3 parts of coupling agent; the second component includes 80-90 parts of silicone oil and 10-15 parts of expanding powder; the elastic glue removing mechanism is used to remove the excess glue on the surface of the conductive layer, the first wrapping device is used to wrap a water-blocking tape on the surface of the conductive layer, the second wrapping device is used to wrap a binding tape on the surface of the water-blocking tape, and the third wrapping device is used to wrap a protective tape on the surface of the binding tape to form the submarine cable composite conductor.

[0025] The submarine cable composite conductor, its preparation method and production device provided by the present application use composite conductor filaments with a copper-clad aluminum structure to prepare a conductive core, greatly reducing the dependence on copper in cable manufacturing, reducing the manufacturing cost of the conductor, and enabling sustainable development of the market; it can also make the submarine cable composite conductor have good flexibility and a light weight, greatly reducing the transportation difficulty and laying difficulty. In addition, the present application fills water-blocking materials in the gaps between the conductor filaments and in the gaps between the water-blocking tape and the conductive layer, and wraps water-blocking materials outside the conductor, and cooperates with semiconductive water-resistant glue with a special component ratio, which can better prevent the intrusion of seawater while maintaining the conductive performance of the conductor, greatly reducing the damage degree of the cable. Description of the Drawings

[0026] To more clearly illustrate the technical solutions of the embodiments of the present application, the accompanying drawings in the embodiments will be briefly introduced below. It should be understood that the following accompanying drawings only show some embodiments of the present application, and thus should not be regarded as limiting the scope. For those of ordinary skill in the art, without creative efforts, other related accompanying drawings can also be obtained based on these drawings.

[0027] Figure 1 It is a schematic cross-sectional structure diagram of a submarine cable composite conductor according to an embodiment of the present application.

[0028] Figure 2 It is a schematic structural diagram of a production device for a submarine cable composite conductor in an embodiment.

[0029] Main element symbol description:

[0030] Submarine cable composite conductor 100 Conductive layer 1 Composite conductor single wire 11 Semiconductor water-resistant glue 2 Water-blocking tape 3 Binding layer 4 Protective layer 5 Twisted body 6 Wire splitter 7 Glue injection mold 8 Glue injection tube 81 Stranding die 9 Mold base 10 Elastic degumming mechanism 12 First wrapping device 13 Second wrapping device 14 Third wrapping device 15

[0031] The following specific embodiments will further illustrate the present application in combination with the above accompanying drawings. Specific embodiments

[0032] The technical solutions in the embodiments of the present application will be clearly and completely described below in combination with the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are only some embodiments of the present application, rather than all embodiments.

[0033] It should be noted that when an element is referred to as "fixed to" another element, it can be directly on the other element or there may also be a middle element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be a middle element at the same time. When an element is considered to be "disposed on" another element, it can be directly disposed on the other element or there may be a middle element at the same time. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are only for the purpose of illustration.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this application belongs. The terms used in the description of the present application in this specification are only for the purpose of describing specific embodiments and are not intended to limit the present application. The term "or / and" used herein includes any and all combinations of one or more of the related listed items.

[0035] Some embodiments of the present application will be described in detail. Without conflict, the following embodiments and the features in the embodiments can be combined with each other.

[0036] See Figure 1, an embodiment of the present application provides a submarine cable composite conductor 100, which includes a conductive layer 1, a water-blocking layer, a binding layer 4, and a protective layer 5 arranged in sequence from inside to outside.

[0037] In the embodiment of the present application, the conductive layer 1 includes a plurality of stranded composite conductor filaments 11. Each composite conductor filament 11 includes an aluminum core and a copper cladding layer. The copper cladding layer is arranged on the surface of the aluminum core and is in close contact with the aluminum core. The composite conductor filament 11 with a copper-clad aluminum structure has good flexibility, good weldability, and excellent electrical properties, and is also beneficial for reducing the weight of the conductor. Under the same cross-section, the weight of the copper-clad aluminum conductor is only about 44% of the weight of the copper conductor, which is more resource-saving and reduces production costs. In addition, during the production process of the composite conductor filament 11 with a copper-clad aluminum structure, the oxidation of the aluminum core can be reduced, and the formation of an oxide film on the surface of the aluminum core can be avoided, which may cause an increase in the AC resistance of the conductor and a reduction in the current-carrying capacity. In one embodiment, the copper cladding layer and the aluminum core can be connected into one body under high pressure. Further, in each composite conductor filament 11, the mass fraction of the copper cladding layer is 18% - 21%, which enables the single filament to have good electrical properties and weldability of copper, and the weight is far lower than that of the copper conductor under the same length, which is more resource-saving and reduces production costs. The material density of the composite conductor filament 11 of the present application is 3.94 g / cm 3 or so, which is far lower than the density of ordinary copper conductors.

[0038] In one embodiment of the present application, a plurality of the composite conductor filaments 11 are stranded to form a plurality of stacked conductive layers 1. The plurality of stacked conductive layers 1 form a conductive core of the submarine cable composite conductor 100, and the stranding directions of adjacent conductive layers 1 are opposite. Further, the stranding pitch diameter ratio of the plurality of conductive layers 1 decreases layer by layer from inside to outside. In this way, the structure of the submarine cable composite conductor 100 can be made more stable. When the submarine cable composite conductor 100 is bent during processing or laying, the structure in which the conductive filaments in adjacent guiding layers are stranded in opposite directions can cancel out the stresses acting on the inside of the conductor, avoiding damage to the single filaments caused by uneven stress, and also avoiding the "loosening back" of the conductor.

[0039] The water-blocking layer includes a semiconductive water-blocking glue 2 and a water-blocking tape 3. The water-blocking tape 3 is coated on the surface of the conductive layer 1, and the semiconductive water-blocking glue 2 is filled between the conductive layer 1 and the water-blocking tape 3 and between a plurality of the composite conductor filaments 11 to prevent the intrusion of water or moisture.

[0040] The semiconductor resistive hydrogel 2 comprises a first component and a second component which are mixed in equal proportion. The first component comprises 60-80 parts of an inorganic modified resin, 10-15 parts of an active fluorocarbon resin, 10-15 parts of a polyethylene waterproofing agent, 30-40 parts of conductive carbon black, 3-5 parts of a stabilizer, and 2-3 parts of a coupling agent. The preparation process of the first component is as follows: 60-80 parts of the inorganic modified resin, 10-15 parts of the active fluorocarbon resin, and 10-15 parts of the polyethylene waterproofing agent are stirred evenly in a constant temperature furnace at about 100 °C at 400-600 revolutions per minute. After the mixed solution is cooled to room temperature (20-30 °C), 30-40 parts of carbon black, 3-5 parts of the stabilizer, and 2-3 parts of the coupling agent are added to the mixed solution. Subsequently, the furnace is evacuated, and stirring is continued at 1000-1200 revolutions per minute for 2-3 h to obtain the first component, which is then injected into a sealed container and stored in a sealed manner. The second component comprises 80-90 parts of silicone oil, 10-15 parts of expansion powder, and 5-8 parts of other materials, and the other materials include an anhydrous component binder. The preparation process of the second component includes: 80-90 parts of silicone oil, 10-15 parts of expansion powder, and 5-8 parts of other materials are stirred in a vacuum furnace at room temperature at 1000-1200 revolutions per minute for 2-3 h to obtain the second component, which is then injected into a sealed container and stored in a sealed manner.

[0041] The first component of the semiconductor resistive hydrogel 2 can endow the colloid with excellent electrical conductivity, non-corrosion and non-oxidation of metal conductors, and excellent ductility. The colloid formed by the first component is in a fluid state. When the second component is mixed with the first component, the combination of silicone oil and expansion powder in the second component can change the colloid formed by the first component from a fluid state to a viscous flow state, and at the same time endow the colloid with water-blocking performance, forming the semiconductor resistive hydrogel 2. After the semiconductor resistive hydrogel 2 is filled in the gaps of the conductor and undergoes a curing and forming process, the water-blocking performance of the conductor 100 of the submarine cable composite material can be effectively improved to meet its use requirements in a 500 m deep sea. Through tests, the physical properties of the formed semiconductor resistive hydrogel 2 are as follows: the tensile strength is 5.5-8.5 MPa, the elongation at break is 500-700%, the tear strength is 30-40 kN / m. When the water seepage pressure of the finished product test is 5 MPa and the continuous test is carried out for 10 days, the water seepage distance is less than 2 m. When the continuous test is carried out for 20 days, the water seepage length is less than 5 m, enabling the conductor 100 of the submarine cable composite material to meet the requirements for use in the deep sea.

[0042] The water-blocking tape 3 is composed of a non-woven fabric, a semi-conductive material, and a highly absorbent material. The material of the binding layer 4 includes a polyester fabric, a semi-conductive adhesive, and a water-absorbing resin. When the submarine cable composite conductor 100 is applied in a submarine cable, a conductor shielding layer is provided on the surface of the conductor. The water-blocking tape 3 is used to block the intrusion of moisture from the gap between the conductor and the conductor shielding layer. The setting of the binding layer 4 can effectively avoid the defects of poor bonding between the water-blocking tape 3 and the conductor shielding layer, insufficient strength and looseness of the water-blocking tape, and uneven surface after wrapping, improve the bonding performance between the conductor and the conductor shielding layer, and also avoid the problem of indentation of the conductor shielding layer caused by the uneven surface of the water-blocking tape, thus improving the manufacturing quality of the submarine cable. In addition, adding conductive carbon black material to the water-blocking tape 3 and the binding layer 4 is beneficial to improving the electrical performance of the submarine cable composite conductor 100.

[0043] The operating environment of the submarine cable is complex and changeable. If it is damaged by external force during daily use, water will enter the cable under pressure along the damage point, causing the submarine cable to fail. Therefore, the submarine cable conductor needs to have good water-blocking performance to prevent the penetration of seawater. In the embodiments of the present application, filling the water-blocking material in the gaps between the conductor filaments and wrapping the water-blocking material around the conductor can better prevent the intrusion of seawater and greatly reduce the degree of cable damage.

[0044] The protective layer 5 is wrapped around the surface of the binding layer 4. Submarine cables are generally produced in large lengths, and a ground turntable is used for wire winding. The submarine cable composite conductor 100 applied to the ground turntable inevitably needs to enter the ground turntable through a platform. During the transfer process, the materials on the surface of the submarine cable composite conductor 100 are easily scratched, which will cause inconvenience in extrusion during the manufacturing process of the submarine cable. In the submarine cable composite conductor 100 of the present application, a protective layer 5 is designed on the surface of the binding layer 4 for protection. The protective layer 5 is formed by wrapping the binding layer 4 with a non-woven fabric mainly composed of synthetic fibers and bonded by an adhesive. The protective layer 5 has good toughness, is strong and durable, and has excellent price performance, etc. It can reduce the wear on the surface of the conductor during the transmission of the submarine cable composite conductor 100, which is beneficial to improving the subsequent manufacturing quality of the submarine cable.

[0045] In the embodiments of the present application, the design process of the conductive core filled with water-blocking glue in the submarine cable composite conductor 100 is as follows:

[0046] 1. The conductor structure design method is: select the DC resistance R B (Ω / km)

[0047] (1)

[0048] where: K1 is the coefficient introduced by the single-filament diameter, metal type, and whether it is tin-plated, and generally takes a value of 1.01 - 1.02;

[0049] K2 is the coefficient introduced by the single-wire diameter and stranding method, and its general value ranges from 1.02 to 1.04;

[0050] K3 is the coefficient introduced whether the insulated conductor cores are cabled or not, and its general value ranges from 1.002 to 1.008;

[0051] A JZ represents the cross-sectional area after compacting;

[0052] R B is the DC resistance at 20°C;

[0053] ρ 20 is the volume resistivity, and its value is 0.02594 Ω·mm 2 / m.

[0054] 2. Calculation of the contour outer diameter:

[0055] According to production, the filling coefficient η = 0.9

[0056]

[0057] where: η is the filling coefficient;

[0058] A JL is the contour cross-sectional area;

[0059] D is the contour diameter.

[0060] 3. Calculation of the single-wire diameter:

[0061] According to the relevant regulations in regular stranding and GB / T 3956-2008, the minimum number of conductor strands is selected for the regular stranding method, and the compacting elongation coefficient ranges from 1.05 to 1.10; the diameter of the composite conductor single wire is calculated from the formula for the compacting elongation coefficient:

[0062]

[0063] where: A Z is the cross-sectional area before compacting;

[0064] d is the single-wire outer diameter;

[0065] μ is the compacting elongation coefficient.

[0066] Through the above formula, the diameter of the composite conductor single wire required for production is obtained.

[0067] The composite conductor 100 of the submarine cable of the present application uses composite conductor single wires with a copper-clad aluminum structure to prepare the conductive core, greatly reducing the dependence on copper in cable manufacturing and enabling sustainable development of the market; it can also endow the composite conductor 100 of the submarine cable with good flexibility and a light weight, greatly reducing the transportation difficulty and laying difficulty; it can also enable the conductor of the composite conductor 100 of the submarine cable to have good weldability, facilitating the production of soft joints in the later stage or during the production process, solving the problem of scrapping of insulated wire cores caused by length changes, resulting in project delays and huge economic losses, and reducing production costs. In addition, the present application uses a water-blocking material to fill the gaps between the conductor single wires and the gaps between the conductive layers, and wraps a water-blocking material around the conductor, which can better prevent the intrusion of seawater and greatly reduce the damage degree of the cable. The component ratio of the semiconductive water-blocking glue in the present application also solves the adverse effects of the current water-blocking glue on the conductivity of the conductor, conductor oxidation, and poor water-blocking effect.

[0068] The embodiment of the present application also provides a manufacturing method for the composite conductor of the submarine cable, which is used to prepare the composite conductor 100 of the submarine cable described in the above embodiment. The manufacturing method of the composite conductor of the submarine cable includes the steps:

[0069] Step 1: A composite conductor wire blank is obtained by cladding an aluminum rod with a copper layer. In the composite conductor wire blank, the mass fraction of the copper layer is 18% - 21%. The composite conductor wire blank is subjected to wire drawing to obtain composite conductor single wires. The composite conductor single wires include an aluminum core and a copper cladding layer. The copper cladding layer is disposed on the surface of the aluminum core and is in close contact with the aluminum core.

[0070] Specifically, oxygen-free copper strip with a purity greater than 99.97% forms a circular tube in a cladding device and is cladded on the surface of the aluminum rod after cleaning. A laser is used to weld the longitudinal seam of the copper tube in a container under a pressure of 10 MPa. The copper layer and the aluminum rod are closely attached and connected into one body under the action of pressure to form a wire blank. Finally, a composite conductor wire blank with a diameter of about 8 mm is obtained through drawing and heat treatment processes. Subsequently, the composite conductor wire blank is sent to a wire drawing machine, and the composite conductor wire blank is drawn into composite conductor single wires through multiple wire drawing dies, and the size of the drawn composite conductor single wires meets the production requirements. During the wire drawing process, a lubricating fluid is used to lubricate and cool the single wires to prevent the single wires from breaking during the drawing process and also avoid the fracture of the copper cladding layer of the composite conductor single wires during the wire drawing process. After the wire drawing process is completed, the obtained composite conductor single wires are sent into an annealing device for annealing heat treatment of the composite conductor single wires to improve the mechanical properties of the composite conductor single wires. The material properties of the composite conductor single wires after annealing heat treatment are: the tensile strength is not less than 200 MPa, the elongation at break is greater than or equal to 15%, and the resistivity is not greater than 0.02594 Ω·mm 2 / m.

[0071] Step 2: Coating semiconductive resistive hydrogel on the surface of the composite conductor single wire. The semiconductive resistive hydrogel includes a first component and a second component mixed in equal proportion. The first component includes 60 - 80 parts of inorganic modified resin, 10 - 15 parts of active fluorocarbon resin, 10 - 15 parts of polyethylene waterproofing agent, 30 - 40 parts of conductive carbon black, 3 - 5 parts of stabilizer, and 2 - 3 parts of coupling agent; the second component includes 80 - 90 parts of silicone oil and 10 - 15 parts of expanding powder.

[0072] Specifically, the preparation process of the first component is as follows: 60 - 80 parts of inorganic modified resin, 10 - 15 parts of active fluorocarbon resin, and 10 - 15 parts of polyethylene waterproofing agent are stirred evenly in a constant temperature furnace at about 100°C at 400 - 600 revolutions per minute. After the mixed solution is cooled to room temperature (20 - 30°C), 30 - 40 parts of carbon black, 3 - 5 parts of stabilizer, and 2 - 3 parts of coupling agent are added to the mixed solution. Subsequently, the furnace is evacuated, and stirring continues at 1000 - 1200 revolutions per minute for 2 - 3 hours to obtain the first component, which is then injected into a sealed container for storage. The second component includes 80 - 90 parts of silicone oil, 10 - 15 parts of expanding powder, and 5 - 8 parts of other materials. The preparation process of the second component includes: 80 - 90 parts of silicone oil, 10 - 15 parts of expanding powder, and 5 - 8 parts of other materials are stirred in a vacuum furnace at room temperature at 1000 - 1200 revolutions per minute for 2 - 3 hours to obtain the second component, which is then injected into a sealed container for storage.

[0073] Before coating the semiconductive resistive hydrogel on the surface of the composite conductor single wire, the first component and the second component are mixed in equal proportion by a two-step method to obtain semiconductive resistive hydrogel with certain viscosity and fluidity. Subsequently, the injection equipment coats the semiconductive resistive hydrogel on the surface of each composite conductor single wire. The semiconductive resistive hydrogel has excellent water swelling performance and is used to fill the gaps between the composite conductor single wires to block the intrusion of water or moisture.

[0074] Step 3: Stranding multiple composite conductor single wires coated with the semiconductive resistive hydrogel to form multiple conductive layers, and the stranding directions of adjacent conductive layers are opposite.

[0075] Specifically, multiple composite conductor single wires are arranged in a stranding device according to a preset rule. Before stranding, the semiconductive resistive hydrogel is evenly coated on the surface of each composite conductor single wire by the injection equipment. Then, during the stranding process of the multiple composite conductor single wires, the uncured semiconductive resistive hydrogel fills the gaps between the multiple composite conductor single wires as the stranding process progresses. Multiple composite conductor single wires are stranded to form multiple conductive layers, obtaining a conductive core. The gaps in the conductive core and the surface of the conductive core are both provided with semiconductive resistive hydrogel.

[0076] In the embodiments of the present application, when multiple composite conductor single wires are stranded to form multiple conductive layers, the stranding directions of adjacent conductive layers are opposite, and the stranding direction of the outermost conductive layer is left-handed. Further, the stranding pitch diameter ratios of the multiple conductive layers gradually decrease from the inside to the outside. The stranding pitch diameter ratio is the ratio of the pitch on this layer to the outer diameter on this layer. The stranding pitch diameter ratio of the innermost conductive layer is less than or equal to 26, and the stranding pitch diameter ratio of the outermost conductive layer is less than or equal to 14. This is beneficial to increasing the bendability and tightness of the conductive layer, thereby improving the mechanical properties of the submarine cable composite conductor 100 prepared.

[0077] Step Four: Wrap a water-blocking tape and a binding layer around the surface of the conductive layer, and the binding layer is located outside the water-blocking tape.

[0078] Specifically, before wrapping the water-blocking tape and the binding layer around the surface of the conductive layer, it is also necessary to scrape off the excess semiconductive water-blocking glue on the surface of the conductive core to make the shape of the conductive core regular, and the composite conductor single wires are still coated in the semiconductive water-blocking glue. Subsequently, the water-blocking tape and the binding layer are wrapped around the surface of the conductive core in sequence, so that the conductive core with multiple conductive layers is tightened, which is beneficial to improving the binding tightness between the semiconductive water-blocking glue and the composite conductor single wires, and also helps the curing and forming of the semiconductive water-blocking glue. Scraping off the excess semiconductive water-blocking glue is beneficial to reducing the problem of unevenness on the surface of the conductive core and improving the wrapping quality of the subsequent water-blocking tape and binding layer.

[0079] The water-blocking tape is composed of a non-woven fabric, a semiconductive material, and a highly water-absorbent material. The material of the binding layer includes a polyester fabric, a semiconductive adhesive, and a water-absorbing resin.

[0080] Step Five: Wrap a protective tape around the surface of the binding layer to form a submarine cable composite conductor.

[0081] Specifically, in the embodiments of the present application, two layers of protective tapes are wrapped around the surface of the binding layer through a wrapping device to form a protective layer of the submarine cable composite conductor 100, so as to achieve full protection of the conductor and reduce the surface wear problem of the conductor during subsequent transportation.

[0082] Further, the method for manufacturing the submarine cable composite conductor of the present application further includes Step Six:

[0083] Dry the submarine cable composite conductor to cure and form the semiconductive water-blocking glue; the drying temperature is 30°C to 40°C, and the drying time is 1 - 2 h.

[0084] Specifically, after the process of wrapping the protective tape is completed, the obtained submarine cable composite conductor is placed in a drying oven for drying treatment. The temperature of the drying oven is adjusted to 30°C to 40°C, and the drying time is 1 - 2 h, so that the semiconductive water-blocking glue in the submarine cable composite conductor is cured and formed.

[0085] After the drying process is completed, a 2m-3m submarine cable composite conductor sample can be cut to check the curing degree of the semi-conductive water-blocking glue inside it. After separating the sample layer by layer, the water-blocking glue between each conductive layer forms a continuous mesh structure, indicating that the curing is complete.

[0086] See also Figure 2 The embodiment of the present application also provides a submarine cable composite conductor production device, which is used to prepare the submarine cable composite conductor described in the above embodiment. The submarine cable composite conductor production device includes a stranded body 6, a branching plate 7, a glue injection mold 8, a stranding mold 9, a mold seat 10, an elastic glue removal mechanism 12, a first wrapping device 13, a second wrapping device 14 and a third wrapping device 15, which are sequentially arranged along the pulling direction of the conductor.

[0087] The twisting body 6, the wire splitting plate 7 and the wire twisting mold 9 are used to twist a plurality of composite conductor monofilaments 11 to form a multi-layer stacked conductive layer 1. The glue injection mold 8 is arranged between the wire splitting plate 7 and the wire twisting mold 9, and is used to apply the semi-conductive resistive water glue 2 to the surface of the composite conductor monofilaments 11 before the composite conductor monofilaments 11 are twisted.

[0088] The semiconductive resistive water glue 2 comprises a first component and a second component mixed in equal proportions, wherein the first component comprises 60 to 80 parts of inorganic modified resin, 10 to 15 parts of active fluorocarbon resin, 10 to 15 parts of polyethylene waterproofing agent, 30 to 40 parts of conductive carbon black, 3 to 5 parts of stabilizer, and 2 to 3 parts of coupling agent; the second component comprises 80 to 90 parts of silicone oil and 10 to 15 parts of expansion powder. The semiconductive resistive water glue 2 obtained by mixing the first component and the second component is delivered to the injection mold 8 through the injection tube 81. When the composite conductor monofilament 11 passes through the injection mold 8, the semiconductive resistive water glue 2 is evenly coated on the surface of the composite conductor monofilament 11. The composite conductor monofilament 11 coated with the semiconductive resistive water glue 2 forms a multilayer conductive layer 1 in the stranding mold 9 and is pulled into the subsequent device. The mold seat 10 is used to install the stranding mold 9 and can also be used to adjust the stranding mold 9 to meet different production requirements.

[0089] The elastic degumming mechanism 12 is arranged at the wire outlet end of the stranded wire die 9 and is used to remove the redundant colloid on the surface of the conductive core formed by the multi-layer conductive layer 1, so as to make the surface shape of the conductive core regular, reduce problems such as bulging and gaps during the subsequent processes of winding water-blocking tapes, binding tapes, etc., and is beneficial to improving the manufacturing quality of the submarine cable conductor. Subsequently, the conductive core formed by the multi-layer conductive layer 1 is successively sent to the first wrapping device 13, the second wrapping device 14, and the third wrapping device 15. The first wrapping device 13 is used to wrap the water-blocking tape 3 onto the surface of the conductive layer 1, the second wrapping device 14 is used to wrap the binding tape onto the surface of the water-blocking tape 3, and the third wrapping device 15 is used to wrap the protective tape onto the surface of the binding tape to form the submarine cable composite conductor 100.

[0090] In the embodiment of the present application, the first wrapping device 13 and the second wrapping device 14 are distributed on opposite sides of the conductor and are correspondingly arranged, so that the wrapping processes of the water-blocking tape and the binding tape are carried out approximately synchronously, which is beneficial to improving the tightening effect of the binding tape on the conductor. Two groups of third wrapping devices 15 are symmetrically arranged on both sides of the conductor and are used to wrap two layers of protective tapes on the surface of the conductor to enhance the protection effect on the conductor.

[0091] The above embodiments are only used to illustrate the technical solutions of the present application and not to limit them. Although the present application has been described in detail with reference to the above preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present application can be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present application.

Claims

1. A submarine cable composite conductor, comprising a conductive layer, a water-blocking layer and a binding layer arranged in sequence from inside to outside, characterized in that: The conductive layer includes multiple composite conductor filaments arranged in a stranded manner. Each composite conductor filament includes an aluminum core and a copper cladding layer, and the copper cladding layer is disposed on the surface of the aluminum core; in each composite conductor filament, the mass fraction of the copper cladding layer is 18% to 21%. The water-blocking layer includes a semiconductive water-blocking glue and a water-blocking tape. The water-blocking tape is wrapped around the surface of the conductive layer, and the semiconductive water-blocking glue is filled between the conductive layer and the water-blocking tape and between multiple composite conductor filaments; the semiconductive water-blocking glue includes a first component and a second component mixed in equal proportion. The first component includes 60 to 80 parts of an inorganic modified resin, 10 to 15 parts of an active fluorocarbon resin, 10 to 15 parts of a polyethylene waterproofing agent, 30 to 40 parts of conductive carbon black, 3 to 5 parts of a stabilizer, and 2 to 3 parts of a coupling agent; the second component includes 80 to 90 parts of silicone oil and 10 to 15 parts of an expanding powder. The material of the binding layer includes a polyester fabric, a semiconductive adhesive, and a water-absorbing resin. The submarine cable composite conductor further includes a protective layer, and the protective layer is wrapped around the surface of the binding layer; the protective layer is formed by wrapping a non-woven fabric mainly composed of fibers and bonded by an adhesive around the binding layer.

2. The submarine cable composite conductor according to claim 1, characterized in that: Multiple composite conductor filaments are stranded to form multiple layers of the conductive layer, and the stranding directions of adjacent conductive layers are opposite.

3. The submarine cable composite conductor according to claim 2, characterized in that: The stranding pitch ratio of multiple layers of the conductive layer decreases layer by layer from the inside to the outside.

4. A manufacturing method of a submarine cable composite conductor, used for preparing the submarine cable composite conductor according to any one of claims 1-3, characterized in that: A composite conductor wire blank is made by cladding an aluminum rod with a copper layer. In the composite conductor wire blank, the mass fraction of the copper layer is 18% to 21%. The composite conductor wire blank is drawn to obtain a composite conductor filament, and the composite conductor filament includes an aluminum core and a copper cladding layer, and the copper cladding layer is disposed on the surface of the aluminum core. Apply the semiconductive water-blocking glue to the surface of the composite conductor filament; the semiconductive water-blocking glue includes a first component and a second component mixed in equal proportion. The first component includes 60 to 80 parts of an inorganic modified resin, 10 to 15 parts of an active fluorocarbon resin, 10 to 15 parts of a polyethylene waterproofing agent, 30 to 40 parts of conductive carbon black, 3 to 5 parts of a stabilizer, and 2 to 3 parts of a coupling agent; the second component includes 80 to 90 parts of silicone oil and 10 to 15 parts of an expanding powder. Strand multiple composite conductor filaments coated with the semiconductive water-blocking glue to form multiple layers of the conductive layer, and the stranding directions of adjacent conductive layers are opposite. Wrap the water-blocking tape and the binding layer around the surface of the conductive layer. The binding layer is located outside the water-blocking tape, and the material of the binding layer includes a polyester fabric, a semiconductive adhesive, and a water-absorbing resin. Wrap a protective tape around the surface of the binding layer to form a submarine cable composite conductor.

5. The manufacturing method of a submarine cable composite conductor according to claim 4, characterized in that It further includes: Dry the submarine cable composite conductor to cure and form the semiconductive water-blocking glue. The drying temperature is 30°C to 40°C, and the drying time is 1 to 2 hours.

6. The manufacturing method of a submarine cable composite conductor according to claim 4, characterized in that: The stranding pitch ratio of multiple layers of the conductive layer decreases layer by layer from the inside to the outside.

7. The manufacturing method of a submarine cable composite conductor according to claim 6, characterized in that: The stranding pitch ratio of the innermost conductive layer is less than or equal to 26, and the stranding pitch ratio of the outermost conductive layer is less than or equal to 14.

8. The manufacturing method of a submarine cable composite conductor according to claim 4, characterized in that: The preparation steps of the first component in the semiconductor resistive hydrogel include: mixing 60-80 parts of inorganic modified resin, 10-15 parts of active fluorocarbon resin, and 10-15 parts of polyethylene waterproofing agent evenly in a constant temperature environment of 100°C at a stirring speed of 400-600 revolutions per minute. After cooling to room temperature, 30-40 parts of carbon black, 3-5 parts of stabilizer, and 2-3 parts of coupling agent are added, and continuous stirring is carried out at a speed of 1000-1200 revolutions per minute for 2-3 hours in a vacuum environment.

9. A production equipment of a submarine cable composite conductor, used for preparing the submarine cable composite conductor according to any one of claims 1-3, characterized in that, The production equipment for the submarine cable composite conductor includes a stranding body, a wire distributing board, a glue injection die, a stranding die, a die holder, an elastic degumming mechanism, a first wrapping device, a second wrapping device, and a third wrapping device arranged in sequence along the pulling direction of the conductor; the stranding body, the wire distributing board, and the stranding die are used for stranding multiple composite conductor single wires to form a conductive layer; the glue injection die is arranged between the wire distributing board and the stranding die and is used for coating the semiconductor resistive hydrogel on the surface of the composite conductor single wire before the stranding of the composite conductor single wire; the semiconductor resistive hydrogel includes a first component and a second component mixed in equal proportions, the first component includes 60-80 parts of inorganic modified resin, 10-15 parts of active fluorocarbon resin, 10-15 parts of polyethylene waterproofing agent, 30-40 parts of conductive carbon black, 3-5 parts of stabilizer, and 2-3 parts of coupling agent; the second component includes 80-90 parts of silicone oil and 10-15 parts of expanding powder; the elastic degumming mechanism is arranged at the outlet end of the stranding die, and the elastic degumming mechanism is used for removing the excess colloid on the surface of the conductive layer. The first wrapping device is used for wrapping a water blocking tape on the surface of the conductive layer, the second wrapping device is used for wrapping a binding tape on the surface of the water blocking tape, and the third wrapping device is used for wrapping a protective tape on the surface of the binding tape to form the submarine cable composite conductor.

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