Submersible multipurpose marine cable and method of manufacturing the same

Abstract

The embodiment of the present application provides a kind of sink and float type multipurpose submarine cable, sink and float type multipurpose submarine cable includes multiple phase cores, phase core includes first foaming layer, the foaming rate of first foaming layer is greater than 90%, multiple phase cores are collectively stranded with light filler to form cable core, cable core outside is covered with second foaming layer, the foaming rate of second foaming layer is greater than 90%, second foaming layer outer layer is covered with insect-proof metal shielding layer, insect-proof metal shielding layer outer layer is covered with non-water-absorbing general plastic sheath.The sink and float type multipurpose submarine cable of the present application can realize the dual function of floating submarine cable and submarine buried cable, can meet different use conditions and realize the laying of different environments, without separately designing and producing different submarine cables, reduce the design, construction, production cost.The embodiment of the present application also provides a kind of manufacturing method of sink and float type multipurpose submarine cable.

Description

Technical Field

[0001] This application relates to the field of new energy, and in particular to a floating multipurpose submarine cable and its manufacturing method. Background Technology

[0002] my country boasts abundant marine resources and a promising future for offshore wind power. The development of offshore wind power relies heavily on submarine cables, which act as the crucial link connecting clean energy from the sea to the onshore power grid. With the rapid development of offshore wind power in recent years, near-shore resources are becoming increasingly scarce. To maximize the utilization of nature's clean energy, offshore wind power will inevitably shift from near-shore to offshore. However, the complex and variable environment of offshore waters necessitates the use of floating wind turbines for energy generation, making the development of lightweight floating submarine cables essential.

[0003] Existing submarine cable patents design cables for single-use conditions, lacking the dual functionality of both submerged and floating applications. Traditional floating submarine cables typically employ a multi-core stranded structure reinforced with steel wire armor and protected with a plastic sheath. During installation, numerous floats are required to achieve buoyancy in seawater, enabling floating transmission. However, this structure is unsuitable for submerged installation; furthermore, transmission capacity is significantly reduced due to buoyancy requirements, hindering high-capacity transmission. Traditional buried submarine cables, on the other hand, use a power core, stranded optical units, and filler material, then reinforced with one or more layers of steel wire armor, asphalt coating, and multiple layers of polypropylene rope. This structure, due to the extensive use of metals, results in a heavy cable that cannot float, limiting its application to a single environment and preventing the realization of multi-purpose submarine cable functionality.

[0004] How to solve the above problems and provide a multi-purpose submarine cable that combines the functions of a floating submarine cable and a buried submarine cable is something that those skilled in the art need to consider. Summary of the Invention

[0005] This application provides a floating multipurpose submarine cable, which includes multiple phase cores. Each phase core includes a first foam layer with a foaming rate greater than 90%. The multiple phase cores are twisted together with a lightweight filler to form a cable core. The cable core is covered with a second foam layer with a foaming rate greater than 90%. The second foam layer is covered with an insect-proof metal shielding layer, and the insect-proof metal shielding layer is covered with a non-absorbent, all-encompassing plastic sheath.

[0006] In one possible implementation, the phase-splitting conductor includes a water-blocking conductor, and a composite co-extruded layer, a first water-blocking layer, a first shielding layer, a second water-blocking layer, a first plastic sheath, a first foaming layer, a second shielding layer, and a second plastic sheath sequentially covering the outside of the water-blocking conductor; the overall plastic sheath is sequentially covered with an armor layer and an outer sheath, and the armor layer includes multiple armor materials and optical units spaced apart between the armor materials.

[0007] In one possible implementation, the materials of the first foam layer and the second foam layer include foamed polyethylene, azobisisobutyronitrile, azodicarbonamide, water-blocking powder, and stabilizer, wherein azobisisobutyronitrile accounts for 1.5%, azodicarbonamide accounts for 1%, water-blocking powder accounts for 2%, stabilizer accounts for 0.5%, foamed polyethylene accounts for 90%, and other components account for 5%; the materials of the first plastic sheath, the second plastic sheath, and the overall plastic sheath include polyethylene, polyisobutylene, stearic acid, and antioxidant, wherein polyisobutylene accounts for 1%, stearic acid accounts for 2%, antioxidant accounts for 1%, polyethylene accounts for 92%, and other components account for 4%.

[0008] This application also provides a method for manufacturing a submersible multi-purpose submarine cable, comprising the following steps:

[0009] Step S1: Add water-blocking adhesive during the stranding of conductor monofilaments, so that the water-blocking adhesive fills between multiple conductor monofilaments, and wrap semi-conductive water-blocking tape around the outside and press it tightly to obtain a water-blocking conductor.

[0010] Step S2: Extruding a composite co-extruded layer covering the water-blocking conductor to form on the outside of the water-blocking conductor;

[0011] Step S3: A first water-blocking layer, a first shielding layer, and a second water-blocking layer are sequentially formed on the outside of the composite co-extruded layer;

[0012] Step S4: Extruding a first plastic protective layer to the outside of the second water-blocking layer;

[0013] Step S5: A first foam layer is extruded on the outside of the first plastic protective layer to form a first foam layer, wherein the foaming degree of the first foam layer is greater than 90%;

[0014] Step S6: A metal strip is longitudinally wrapped around the outside of the first foam layer, and the seam of the metal strip is welded. Then, the metal strip is rolled into a wrinkled structure through a spiral die to obtain the outer metal layer.

[0015] Step S7: A second plastic protective layer is extruded on the outside of the outer metal layer to obtain the phase-separating wire core;

[0016] Step S8: Twist the multiple phase cores together with lightweight filler, and then use wrapping tape to shape them to obtain the cable cores;

[0017] Step S9: A second foam layer is extruded to form on the outside of the cable core, wherein the foaming degree of the second foam layer is greater than 90%;

[0018] Step S10: An insect-proof metal shielding layer is formed by winding it around the outside of the second foaming layer, and a bulk plastic protective layer is formed by extruding it on the outside of the insect-proof metal shielding layer.

[0019] Step S11: An armor layer containing a light unit and a filler strip armor layer is provided on the outside of the overall plastic protective layer, and an outer sheath layer is provided on the outside of the armor layer.

[0020] In one possible implementation, in step S1: a multi-disc frame stranding machine is used to strand multiple conductor monofilaments to form a water-blocking conductor. During the stranding process, two stranding molds are provided for each layer. Water-blocking adhesive is added at the stranding point of the first stranding mold of each layer of conductor monofilament stranding, so that the water-blocking adhesive fills the gaps between the multiple conductor monofilaments. A layer of semi-conductive water-blocking tape is wrapped or longitudinally wrapped. Under the tight pressure of the second stranding mold of each layer, the water-blocking tape and the water-blocking adhesive together form a water-blocking layer, and the water-blocking conductor is obtained.

[0021] In one possible implementation, in step S2, the composite co-extruded layer is a composite of a conductor shielding layer, a cross-linked polyethylene insulation layer, and an insulation shielding layer. Three specially designed extruders and die heads are used to simultaneously extrude the conductor shielding layer, the cross-linked polyethylene insulation layer, and the insulation shielding layer outside the water-blocking conductor. The conductor shielding layer, the cross-linked polyethylene insulation layer, and the insulation shielding layer all consist of polyethylene. The extrusion temperature of the conductor shielding layer and the insulation shielding layer is 80°C to 110°C from the machine body to the die head. The melting temperature of the conductor shielding layer and the insulation shielding layer is not greater than 110°C. The cross-linked polyethylene insulation layer… The extrusion temperature of the insulation layer is 90°C to 120°C from the machine body to the die head, and the melting temperature of the cross-linked polyethylene insulation layer is no greater than 130°C. After the co-extrusion of the composite co-extruded layer is completed, the cross-linked polyethylene insulation layer is chemically cross-linked in a nitrogen atmosphere in a sealed multi-section pipe. The nitrogen pressure ranges from 8 Bar to 10 Bar, and the temperature range of each section of the pipe is from 250°C to 400°C. Subsequently, it is cooled and shaped by nitrogen gas cooling or water cooling to obtain the composite co-extruded layer. In step S3, the first water-blocking layer, the first shielding layer, and the second water-blocking layer are sequentially wrapped on the outside of the composite co-extruded layer using a wrapping machine.

[0022] In one possible implementation, in step S4, the first plastic protective layer is extruded onto the outside of the second water-blocking layer using an extruder. The temperature of the extruder from the machine body to the die head is 130°C to 220°C. After the first plastic protective layer is extruded, it is placed into the first cooling water tank for preliminary fixing and shaping. The temperature range of the first cooling water tank is 70°C to 80°C. Then, it is placed into the second cooling water tank for a second step of cooling. The temperature of the second cooling water tank is below 25°C. In step S7, the second plastic protective layer is extruded onto the outside of the outer metal layer using an extruder. The temperature of the extruder from the machine body to the die head is 130°C to 220°C. After the second plastic protective layer is extruded, it is placed into the first cooling water tank for preliminary fixing and shaping. The temperature range of the first cooling water tank is 70°C to 80°C. Then, it is placed into the second cooling water tank for a second step of cooling. The temperature of the second cooling water tank is below 25°C.

[0023] In one possible implementation, in step S5, nitrogen gas is injected during the plastic extrusion process using an extruder and an injection machine to complete the extrusion of the foamed material, and then the material is cooled by water to obtain the first foamed layer; in step S9, nitrogen gas is injected during the plastic extrusion process using an extruder and an injection machine to complete the extrusion of the foamed material, and then the material is cooled by water to obtain the second foamed layer.

[0024] In one possible implementation, in step S6, the crimping depth ranges from 0.5 mm to 1.5 mm, and each complete thread pitch is 25 to 35 mm; in step S8, a cabling machine is used to twist multiple segments of the phase conductors and the lightweight filler together and wrap them with wrapping tape for shaping, wherein the twisting pitch ratio is 20 to 25, and the wrapping tape overlap rate is 30% to 45%.

[0025] In one possible implementation, in step S10, the insect-proof metal shielding layer is longitudinally wrapped and pressed tightly onto the outside of the second foaming layer, with the edges of the insect-proof metal shielding layer overlapping by 10mm to 20mm. After the insect-proof metal shielding layer is wound, the material is directly fed into the extruder, and the bundled plastic protective layer is extruded onto the outside of the insect-proof metal shielding layer. In step S11, an 800-type large armoring machine is used to twist the optical unit and armoring material onto the outside of the bundled plastic protective layer, and then a winding machine is used to wrap the outer sheath around the outside of the armoring layer for tightening and protection. The twisting pitch ratio is 8 to 10, the winding pitch of the outer sheath ranges from 200mm to 300mm, and the diameter of the optical unit is less than 10% of the diameter of the armoring material.

[0026] Compared to existing technologies, the floating multi-purpose submarine cable and its manufacturing method provided in this application, by achieving the dual functions of floating and burying the cable, improves the laying efficiency and extends the service life of the product, thereby effectively reducing the product cost and allowing for a larger capacity. The floating multi-purpose submarine cable of this application can achieve the dual functions of a floating submarine cable and a buried submarine cable, meeting different usage conditions and enabling laying in different environments. This avoids the need for separate design and production of different submarine cables, reducing design, construction, and production costs and minimizing resource waste. Simultaneously, the floating multi-purpose submarine cable of this application solves the problem of insufficient buoyancy in large-section submarine cables requiring numerous auxiliary accessories. The floating multi-purpose submarine cable can achieve levitation using only 1 / 10 the number of floats required for traditional floating submarine cables, reducing construction workload and production costs, and lowering the risk of the floats being damaged by marine organisms and losing their effectiveness. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of a floating multipurpose submarine cable according to an embodiment of this application.

[0028] Figure 2 This is a schematic flowchart illustrating the manufacturing method of the floating multipurpose submarine cable according to an embodiment of this application.

[0029] Explanation of main component symbols

[0030] Floating-type multipurpose submarine cable 1

[0031] 10 cores of the cable

[0032] Lightweight filler 11

[0033] Phase splitting conductor 12

[0034] Water-blocking conductor 120

[0035] Conductor monofilament 1201

[0036] Water-blocking adhesive 1202

[0037] Water barrier 1203

[0038] Composite co-extruded layer 121

[0039] First water-blocking layer 122

[0040] First shielding layer 123

[0041] Second water-blocking layer 124

[0042] First plastic sheath 125

[0043] First foaming layer 126

[0044] Second shielding layer 127

[0045] Second plastic protective layer 128

[0046] 13 layers of packaging tape

[0047] Second foaming layer 14

[0048] Insect-proof metal shielding layer 15

[0049] 16-layer plastic protective layer

[0050] Armor layer 17

[0051] Optical Unit 171

[0052] Armor Material 172

[0053] Outer layer 18

[0054] The following detailed description, in conjunction with the accompanying drawings, will further illustrate this application. Detailed Implementation

[0055] The following description will refer to the accompanying drawings to provide a more complete picture of the present application. The drawings illustrate exemplary embodiments of the present application. However, the present application may be implemented in many different forms and should not be construed as limited to the exemplary embodiments set forth herein. These exemplary embodiments are provided to make the present application thorough and complete, and to fully convey the scope of the present application to those skilled in the art. Similar reference numerals denote the same or similar components.

[0056] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to limit the application. As used herein, unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” are intended to also include the plural forms. Furthermore, when used herein, “comprising” and / or “including” and / or “having,” integers, steps, operations, components, and / or components, but does not exclude the presence or addition of one or more other features, regions, integers, steps, operations, components, and / or groups thereof.

[0057] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. Furthermore, unless expressly defined herein, terms such as those defined in a general dictionary should be interpreted as having the same meaning as they have in the relevant art and in the content of this application, and will not be interpreted as having an idealized or overly formal meaning.

[0058] The specific embodiments of this application will be further described in detail below with reference to the accompanying drawings.

[0059] like Figure 1As shown, this application embodiment provides a floating multipurpose submarine cable 1. The floating multipurpose submarine cable 1 includes multiple phase cores 12. Each phase core 12 includes a first foam layer 126 with a foaming rate greater than 90%. The multiple phase cores 12 are twisted together with a lightweight filler 11 to form a cable core 10. The cable core 10 is covered with a second foam layer 14 with a foaming rate greater than 90%. The second foam layer 14 is covered with an insect-proof metal shielding layer 15, and the insect-proof metal shielding layer 15 is covered with a non-absorbent, all-encompassing plastic sheath 16.

[0060] In one embodiment, the phase conductor 12 includes a water-blocking conductor 120, and a composite co-extruded layer 121, a first water-blocking layer 122, a first shielding layer 123, a second water-blocking layer 124, a first plastic sheath 125, a first foaming layer 126, a second shielding layer 127, and a second plastic sheath 128 sequentially covering the outside of the water-blocking conductor 120.

[0061] In one embodiment, multiple phase-separated cores 12 are twisted together with lightweight filler 11 and wrapped and shaped by a wrapping layer 13 to form a cable core 10. A second foaming layer 14 is disposed on the outside of the wrapping layer 13, an insect-proof metal shielding layer 15 is disposed on the outside of the second foaming layer 14, and a bulk plastic sheath 16 is disposed on the outside of the insect-proof metal shielding layer 15. An armor layer 17 and an outer sheath 18 are sequentially covered on the bulk plastic sheath 16. The armor layer 17 includes multiple armor materials 172 and optical units 171 spaced apart between the armor materials 172.

[0062] In one embodiment, a lightweight filler 11 is used for filling, making the cable core 10 more rounded and lighter. The wrapping layer 13 can be composed of synthetic fibers, adhesives, etc., and can serve as a stabilizing layer for the cable core 10. The insect-proof metal shielding layer 15 is a metal composite tape structure, which can be a high-performance plastic-copper-aluminum composite tape, wherein plastic accounts for 2 components, copper tape accounts for 2 components, and aluminum tape accounts for 1 component. The surface of the copper tape is aluminum, and the aluminum is plastic. The three materials are tightly bonded together to form a metal composite tape. The insect-proof metal shielding layer 15 is formed by longitudinal wrapping.

[0063] In one embodiment, the optical unit 171 and armor material 172 are armored onto a bulk plastic sheath 16 to form an armor layer 17. The optical unit 171 may be housed within a stainless steel tube to protect it from damage during the armoring process. The armor material 172 may be made of copper wire, steel wire, aluminum wire, or high-strength fiber strips. The outer sheath 18 is formed by winding one or more layers of polypropylene rope to protect the armor layer 17.

[0064] In one embodiment, the water-blocking conductor 120 includes multiple stranded conductor filaments 1201, with water-blocking adhesive 1202 filling the spaces between them, so that each conductor filament 1201 is wrapped in water-blocking adhesive 1202. A water-blocking tape 1203 is then wrapped around the stranded conductor filaments 1201 and the water-blocking adhesive 1202. The water-blocking adhesive 1202 mainly comprises silicone rubber and carbon black, with the content of silicone rubber and carbon black ranging from 60% to 80%. The moisture content of the water-blocking adhesive 1202 is no more than 0.1%. The water-blocking adhesive 1202, in conjunction with the water-blocking tape 1203, achieves the water-blocking performance of the water-blocking conductor 120.

[0065] In one embodiment, a composite co-extruded layer 121 is wrapped around the outside of the water-blocking conductor 120. The composite co-extruded layer 121 is a composite of a conductor shielding layer, a cross-linked polyethylene insulation layer, and an insulation shielding layer. The composite co-extruded layer 121 may be composed of a semiconducting water-blocking tape, an extruded conductor semiconducting material, an extruded insulation material, and an extruded insulating semiconducting material.

[0066] In one embodiment, the first water-blocking layer 122 and the second water-blocking layer 124 can be a wrapping structure, formed by winding a high-strength water-blocking tape 1203 with excellent water-blocking performance; wherein, the water-blocking tape 1203 is composed of polyester fabric, semi-conductive adhesive, high-speed expanding water-absorbing resin, etc. The first water-blocking layer 122 is wound on the outside of the composite co-extruded layer 121, and the second water-blocking layer 124 is wound on the outside of the first shielding layer 123, serving as a longitudinal water-blocking structure.

[0067] In one embodiment, the first shielding layer 123 and the second shielding layer 127 may be formed by winding a metal strip, wherein the metal strip may be a low-resistance, high-efficiency metal strip or a metal composite strip with excellent water-blocking performance; the first shielding layer 123 and the second shielding layer 127 are wound by the metal strip in a wrapping or longitudinal wrapping manner, wherein the first shielding layer 123 is wound on the outside of the first water-blocking layer 122, and the second shielding layer 127 is wound on the outside of the first foaming layer 126.

[0068] In one embodiment, the materials of the first foam layer 126 and the second foam layer 14 include foamed polyethylene, azobisisobutyronitrile, azodicarbonamide, water-blocking powder, and a stabilizer. The proportions are: azobisisobutyronitrile 1.5%, azodicarbonamide 1%, water-blocking powder 2%, stabilizer 0.5%, foamed polyethylene 90%, and other components 5%. The first foam layer 126 is disposed outside the first plastic sheath 125, and the second foam layer 14 is disposed outside the wrapping layer 13. The first foam layer 126 and the second foam layer 14 serve as the main floating functional layers in the submersible multipurpose submarine cable 1, providing buoyancy for the submersible multipurpose submarine cable 1.

[0069] In one embodiment, the materials of the first plastic sheath 125, the second plastic sheath 128, and the all-inclusive plastic sheath 16 include polyethylene, polyisobutylene, stearic acid, and antioxidants, wherein polyisobutylene accounts for 1%, stearic acid accounts for 2%, antioxidants account for 1%, polyethylene accounts for 92%, and other components account for 4%. The first plastic sheath 125 is disposed outside the second water-blocking layer 124, the second plastic sheath 128 is disposed outside the second shielding layer 127, and the all-inclusive plastic sheath 16 is disposed outside the insect-proof metal shielding layer 15. The first plastic sheath 125, the second plastic sheath 128, and the all-inclusive plastic sheath 16 can serve as water-blocking protective layers.

[0070] Further integration Figure 2 As shown in the embodiments of this application, a method for manufacturing a submersible multi-purpose submarine cable is also provided, comprising the following steps:

[0071] Step S1: To manufacture a water-blocking conductor, water-blocking adhesive is added during the stranding of conductor monofilaments to fill the spaces between multiple conductor monofilaments. Semiconductor water-blocking tape is then wrapped around the outside and pressed tightly to manufacture the water-blocking conductor.

[0072] In one embodiment, a multi-disc frame stranding machine is used to strand multiple conductor monofilaments to form a water-blocking conductor. During the stranding process, two stranding molds are provided for each layer. Water-blocking adhesive is added at the stranding point of the first stranding mold of each layer of conductor monofilament stranding, so that the water-blocking adhesive fills the gaps between the multiple conductor monofilaments. Then, a layer of semi-conductive water-blocking tape is wrapped or longitudinally wrapped. Under the tight pressure of the second stranding mold of each layer, the water-blocking tape and the water-blocking adhesive together form a water-blocking layer, and the water-blocking conductor is obtained.

[0073] Step S2: The composite co-extruded layer is formed by extrusion on the outside of the water-blocking conductor.

[0074] In one embodiment, the composite co-extruded layer is a composite of a conductor shielding layer, a cross-linked polyethylene insulation layer, and an insulation shielding layer. Three specially designed extruders and die heads are used to simultaneously extrude the conductor shielding layer, the cross-linked polyethylene insulation layer, and the insulation shielding layer outside the water-blocking conductor. The conductor shielding layer, the cross-linked polyethylene insulation layer, and the insulation shielding layer all contain polyethylene. The extrusion temperature of the conductor shielding layer and the insulation shielding layer is 80°C to 110°C from the machine body to the die head, and the melt temperature of the conductor shielding layer and the insulation shielding layer is no greater than 110°C. The extrusion temperature of the cross-linked polyethylene insulation layer is 90°C to 120°C from the machine body to the die head, and the melt temperature of the cross-linked polyethylene insulation layer is no greater than 130°C. After the composite co-extruded layer is co-extruded, the cross-linked polyethylene insulation layer undergoes a chemical cross-linking process in a nitrogen atmosphere within a sealed multi-section pipe. The nitrogen pressure ranges from 8 Bar to 10 Bar, and the temperature range of each section of the pipe is from 250°C to 400°C. The temperature of the multiple sections of the pipe is set in a wave-like pattern of first decreasing, then increasing, then decreasing again, and then increasing again. Subsequently, the composite co-extruded layer is obtained by cooling and molding with nitrogen or water.

[0075] Step S3: Sequentially cover the outside of the composite co-extruded layer with a first water-blocking layer, a first shielding layer, and a second water-blocking layer.

[0076] In one embodiment, a wrapping machine is used to sequentially wrap the first water-blocking layer, the first shielding layer, and the second water-blocking layer on the outside of the composite co-extruded layer.

[0077] Step S4: Extrude a first plastic protective layer on the outside of the second water-blocking layer.

[0078] In one embodiment, an extruder is used to extrude the first plastic protective layer outside the second water-blocking layer. The temperature of the extruder from the machine body to the die head is 130°C to 220°C. After the first plastic protective layer is extruded, it is placed into the first cooling water tank for preliminary fixing and shaping. The temperature range of the first cooling water tank is 70°C to 80°C. Then, it is placed into the second cooling water tank for a second cooling step. The temperature of the second cooling water tank is below 25°C. After the second cooling, it enters the multi-drive integrated storage disk to complete the manufacturing of the first plastic protective layer.

[0079] Step S5: A first foam layer is formed by extruding on the outside of the first plastic protective layer, and the foaming degree of the first foam layer is greater than 90%.

[0080] In one embodiment, a foaming material is extruded by injecting nitrogen gas during the plastic extrusion process using an extruder and a gas injection machine, and then the material is cooled by water to obtain the first foaming layer.

[0081] Step S6: A metal strip is longitudinally wrapped around the outside of the first foam layer, and the seam of the metal strip is welded. Then, the metal strip is rolled into a wrinkled structure by a spiral die to obtain the outer metal layer.

[0082] In one embodiment, the crimping depth ranges from 0.5 mm to 1.5 mm, and each complete thread pitch is from 25 mm to 35 mm.

[0083] Step S7: A second plastic protective layer is extruded on the outside of the outer metal layer to obtain the phase-separating wire core.

[0084] In one embodiment, an extruder is used to extrude the second plastic sheath over the outer metal layer. The temperature of the extruder from the machine body to the die head is 130°C to 220°C. After the second plastic sheath is extruded, it is placed in a first cooling water tank for initial fixing and shaping. The temperature range of the first cooling water tank is 70°C to 80°C. Then, it is placed in a second cooling water tank for a second cooling step. The temperature of the second cooling water tank is below 25°C. After the second cooling, it enters a multi-drive integrated storage disk to complete the manufacturing of the second plastic sheath.

[0085] Step S8: Twist the multiple phase cores together with lightweight filler, and then use wrapping tape to shape them into cable cores.

[0086] In one embodiment, the phase core is cut into multiple segments, and the multiple segments of the phase core and the lightweight filler are twisted together using a cabling machine and wrapped and shaped with wrapping tape. The twisting pitch ratio is 20 to 25, and the wrapping overlap rate of the wrapping tape is 30% to 45%.

[0087] Step S9: A second foam layer is extruded to form on the outside of the cable core.

[0088] In one embodiment, a foaming material is extruded by injecting nitrogen gas during the plastic extrusion process using an extruder and a gas injection machine, and then the material is cooled by water to obtain the second foaming layer.

[0089] Step S10: An insect-proof metal shielding layer is formed by winding it around the outside of the second foaming layer, and a monolithic plastic protective layer is formed by extruding it on the outside of the insect-proof metal shielding layer.

[0090] In one embodiment, a serial production method is adopted to produce the insect-proof metal shielding layer and the bundled plastic sheath simultaneously, saving the turnaround time and reducing energy consumption. The insect-proof metal shielding layer is longitudinally wrapped and tightly pressed onto the outside of the second foaming layer, with the edges of the insect-proof metal shielding layer overlapping by 10mm to 20mm. After the insect-proof metal shielding layer is wound, the material is directly fed into the extruder, and the manufacturing of the bundled plastic sheath is completed in step 4.

[0091] Step S11: An armor layer containing a light unit and a filler strip armor layer is provided on the outside of the overall plastic protective layer, and an outer sheath layer is provided on the outside of the armor layer.

[0092] In one embodiment, a serial production method is adopted to simultaneously complete the optical unit, the filler strip armor layer, and the outer sheath. An 800-type large armoring machine is used to twist the prepared optical unit and armor material onto the outside of the overall plastic protective layer. Then, a winding machine is used to wrap the outer sheath around the outside of the armor layer for tightening and protection. The twisting pitch ratio is 8 to 10, the winding pitch of the outer sheath ranges from 200 mm to 300 mm, and the diameter of the optical unit is less than 10% of the diameter of the armor material to protect the optical unit from damage.

[0093] Compared to existing technologies, the floating multi-purpose submarine cable and its manufacturing method provided in this application improve the laying efficiency and extend the service life of the product by realizing the dual functions of floating and burying the submarine cable, thereby effectively reducing the product cost. The floating multi-purpose submarine cable of this application can realize the dual functions of a floating submarine cable and a buried submarine cable, meeting different usage conditions and enabling laying in different environments. This avoids the need for separate design and production of different submarine cables, reducing design, construction, and production costs, and minimizing resource waste. Simultaneously, the floating multi-purpose submarine cable of this application solves the defect of insufficient buoyancy in large-section submarine cables requiring numerous auxiliary accessories. The floating multi-purpose submarine cable can achieve levitation using only 1 / 10 the number of floats of a traditional floating submarine cable, reducing construction workload and production costs, and lowering the risk of the floats being damaged by marine organisms and losing their effectiveness.

[0094] The specific embodiments of this application have been described above with reference to the accompanying drawings. However, those skilled in the art will understand that various changes and substitutions can be made to the specific embodiments of this application without departing from the scope of this application. All such changes and substitutions fall within the scope defined by this application.

Claims

1. A floating multi-purpose submarine cable, characterized in that, The floating multipurpose submarine cable includes multiple phase cores, each phase core including a first foam layer with a foaming rate greater than 90%. The multiple phase cores are twisted together with lightweight filler to form a cable core. The cable core is covered with a second foam layer with a foaming rate greater than 90%. The second foam layer is covered with an insect-proof metal shielding layer. The insect-proof metal shielding layer is covered with a non-absorbent, all-encompassing plastic sheath. The all-encompassing plastic sheath is covered with an armor layer and an outer sheath layer in sequence.

2. The submersible multi-purpose submarine cable as described in claim 1, characterized in that, The phase-splitting conductor includes a water-blocking conductor, and a composite co-extruded layer, a first water-blocking layer, a first shielding layer, a second water-blocking layer, a first plastic sheath, a first foaming layer, a second shielding layer, and a second plastic sheath sequentially covering the outside of the water-blocking conductor; the armor layer includes multiple armor materials and optical units spaced apart between the armor materials.

3. The submersible multi-purpose submarine cable as described in claim 2, characterized in that, The materials of the first foam layer and the second foam layer include foamed polyethylene, azobisisobutyronitrile, azodicarbonamide, water-blocking powder, and stabilizer, wherein azobisisobutyronitrile accounts for 1.5%, azodicarbonamide accounts for 1%, water-blocking powder accounts for 2%, stabilizer accounts for 0.5%, foamed polyethylene accounts for 90%, and other components account for 5%; the materials of the first plastic sheath, the second plastic sheath, and the overall plastic sheath include polyethylene, polyisobutylene, stearic acid, and antioxidant, wherein polyisobutylene accounts for 1%, stearic acid accounts for 2%, antioxidant accounts for 1%, polyethylene accounts for 92%, and other components account for 4%.

4. A method for manufacturing a submersible multipurpose submarine cable, characterized in that, The method for manufacturing the submersible multipurpose submarine cable is used to manufacture the submersible multipurpose submarine cable as described in any one of claims 1 to 3, and the method for manufacturing the submersible multipurpose submarine cable includes the following steps: Step S1: Add water-blocking adhesive during the stranding of conductor monofilaments, so that the water-blocking adhesive fills between multiple conductor monofilaments, and wrap semi-conductive water-blocking tape around the outside and press it tightly to obtain a water-blocking conductor. Step S2: Extruding a composite co-extruded layer covering the water-blocking conductor to form on the outside of the water-blocking conductor; Step S3: A first water-blocking layer, a first shielding layer, and a second water-blocking layer are sequentially formed on the outside of the composite co-extruded layer; Step S4: Extruding a first plastic protective layer to the outside of the second water-blocking layer; Step S5: A first foam layer is extruded on the outside of the first plastic protective layer to form a first foam layer, wherein the foaming degree of the first foam layer is greater than 90%; Step S6: A metal strip is longitudinally wrapped around the outside of the first foam layer, and the seam of the metal strip is welded. Then, the metal strip is rolled into a wrinkled structure through a spiral die to obtain the outer metal layer. Step S7: A second plastic sheath is extruded to form on the outside of the outer metal layer to obtain the phase-separating wire core; Step S8: Twist the multiple phase cores together with lightweight filler, and then use wrapping tape to shape them to obtain the cable cores; Step S9: A second foam layer is extruded to form on the outside of the cable core, wherein the foaming degree of the second foam layer is greater than 90%; Step S10: An insect-proof metal shielding layer is formed by winding it around the outside of the second foaming layer, and a bulk plastic protective layer is formed by extruding it on the outside of the insect-proof metal shielding layer. Step S11: An armor layer containing a light unit and a filler strip armor layer is provided on the outside of the overall plastic protective layer, and an outer sheath layer is provided on the outside of the armor layer.

5. The manufacturing method of the submersible multi-purpose submarine cable as described in claim 4, characterized in that, In step S1: A multi-disc frame stranding machine is used to strand multiple conductor monofilaments to form a water-blocking conductor. During the stranding process, two stranding molding dies are provided for each layer. Water-blocking adhesive is added at the stranding point of the first stranding molding die in each layer of conductor monofilament stranding, so that the water-blocking adhesive fills the gaps between the multiple conductor monofilaments. A layer of semi-conductive water-blocking tape is wrapped or longitudinally wrapped. Under the tight pressure of the second twisting molding die of each layer, the water-blocking tape and the water-blocking adhesive form a water-blocking layer together, and the water-blocking conductor is obtained.

6. The manufacturing method of the submersible multi-purpose submarine cable as described in claim 4, characterized in that: In step S2, the composite co-extruded layer is a composite of a conductor shielding layer, a cross-linked polyethylene insulation layer, and an insulation shielding layer. Three specially designed extruders and die heads are used to simultaneously extrude the conductor shielding layer, the cross-linked polyethylene insulation layer, and the insulation shielding layer outside the water-blocking conductor. The conductor shielding layer, the cross-linked polyethylene insulation layer, and the insulation shielding layer all contain polyethylene. The extrusion temperature of the conductor shielding layer and the insulation shielding layer is 80°C to 110°C from the machine body to the die head, and the melting temperature of the conductor shielding layer and the insulation shielding layer is no greater than 110°C. The extrusion temperature of the cross-linked polyethylene insulation layer is 90°C to 120°C from the machine body to the die head, and the melting temperature of the cross-linked polyethylene insulation layer is no greater than 130°C. After the composite co-extruded layer is co-extruded, the cross-linked polyethylene insulation layer undergoes a chemical cross-linking process under a nitrogen atmosphere in a sealed multi-section pipe. The nitrogen pressure ranges from 8 Bar to 10 Bar, and the temperature range of each section of the pipe is from 250°C to 400°C. Subsequently, it is cooled and molded by nitrogen gas cooling or water cooling to obtain the composite co-extruded layer. In step S3, a wrapping machine is used to sequentially wrap the first water-blocking layer, the first shielding layer, and the second water-blocking layer on the outside of the composite co-extruded layer.

7. The manufacturing method of the submersible multi-purpose submarine cable as described in claim 4, characterized in that: In step S4, the first plastic protective layer is extruded outside the second water-blocking layer using an extruder. The temperature of the extruder from the machine body to the die head is 130°C to 220°C. After the first plastic protective layer is extruded, it is placed into the first cooling water tank for preliminary fixing and shaping. The temperature range of the first cooling water tank is 70°C to 80°C. Then, it is placed into the second cooling water tank for the second cooling step. The temperature of the second cooling water tank is below 25°C. In step S7, the second plastic protective layer is extruded from the outer metal layer using an extruder. The temperature of the extruder from the machine body to the die head is 130°C to 220°C. After the second plastic protective layer is extruded, it is placed into the first cooling water tank for preliminary fixing and shaping. The temperature range of the first cooling water tank is 70°C to 80°C. Then, it is placed into the second cooling water tank for the second cooling step. The temperature of the second cooling water tank is below 25°C.

8. The method for manufacturing a submersible multipurpose submarine cable as described in claim 4, characterized in that: In step S5, nitrogen gas is injected during the plastic extrusion process by using an extruder and an injection machine to complete the extrusion of the foam material, and then the first foam layer is obtained by water cooling. In step S9, nitrogen gas is injected during the plastic extrusion process by the extruder and the gas injection machine to complete the extrusion of the foam material, and then the second foam layer is obtained by water cooling.

9. The method for manufacturing a submersible multipurpose submarine cable as described in claim 4, characterized in that: In step S6, the crimping depth ranges from 0.5 mm to 1.5 mm, and each complete thread pitch is 25 to 35 mm. In step S8, a cabling machine is used to twist together multiple segments of the phase conductor and the lightweight filler, and then wraps and shapes them with wrapping tape. The twisting pitch ratio is 20 to 25, and the wrapping tape overlap rate is 30% to 45%.

10. The method for manufacturing a submersible multipurpose submarine cable as described in claim 4, characterized in that: In step S10, the insect-proof metal shielding layer is longitudinally wrapped and pressed tightly onto the outside of the second foaming layer, with the edges of the insect-proof metal shielding layer overlapping by 10mm to 20mm. After the insect-proof metal shielding layer is wound, the material is directly fed into the extruder, and the overall plastic protective layer is extruded on the outside of the insect-proof metal shielding layer. In step S11, an 800-type large armoring machine is used to twist the optical unit and armoring material together on the outside of the overall plastic protective layer. Then, a winding machine is used to wrap the outer layer around the outside of the armoring layer for tightening and protection. The twisting pitch ratio is 8 to 10, the winding pitch of the outer layer is 200 mm to 300 mm, and the diameter of the optical unit is less than 10% of the diameter of the armoring material.

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