Waterproof flame-retardant cable

Abstract

The application relates to the technical field of cable materials, and particularly discloses a waterproof and flame-retardant cable. The cable comprises a conductive core, an outer wrapping material layer wrapped outside the conductive core and a filling layer filled between the outer wrapping material layer and the conductive core; wherein the filling layer is prepared from the following raw materials in parts by weight, 100-160 parts of epoxy resin, 60-120 parts of eighty-seven fluorodecyl cage polysilsesquioxane, 50-100 parts of polytetrafluoroethylene and 1-3 parts of silica gel powder; and the outer wrapping material comprises a polycarbonate crosslinked polyethylene compound. The cable prepared in the application can be applied to various places with high temperature and high humidity, has good waterproof and flame-retardant properties, the outer wrapping material of the cable has high strength, the filler in the cable can seep out to repair the damaged part when the cable is damaged, so that the water resistance and the flame-retardant property of the cable can be maintained for a long time, and the durability of the cable is remarkably enhanced.

Description

Technical Field

[0001] This application relates to the field of cable material technology, and more specifically, to a waterproof and flame-retardant cable and its preparation method. Background Technology

[0002] With industrial development and widespread electricity supply, the demand for cables remains high. Due to the extremely high safety requirements of cables, some aging cables that lose their safety need constant replacement, resulting in significant waste. Therefore, the requirements for cable products are becoming increasingly diverse, including properties such as resistance to damp heat, corrosion, water, fatigue, and flame retardancy, with a service life ideally exceeding twenty years. Modern cables often employ a double-layer structure: the inner conductive core provides conductivity, while the outer layer ensures corrosion resistance, flame retardancy, water resistance, and mechanical properties such as abrasion resistance and tensile strength. Because the outer cable sheath is highly likely to come into direct contact with harsh environments such as acids, alkalis, and humidity, it requires high performance in terms of heat resistance, corrosion resistance, abrasion resistance, and flexibility. Especially when the cable sheath is damaged by external forces, the filler leaks at the point of breakage, exposing the conductors and causing serious safety hazards and loss of waterproof and flame-retardant properties, ultimately necessitating replacement with a new cable.

[0003] In summary, the current application situation is that once the cable's outer sheath is damaged, the cable's service life becomes extremely limited. Therefore, simply improving the strength of the outer sheath is clearly insufficient. Further solutions are needed to address the technical problems of reduced waterproof and flame-retardant properties and shortened cable life after sheath damage, through the shaping of the filler material after damage and the development of more durable outer sheath materials. Summary of the Invention

[0004] To address the problem of cable filler becoming unshaped after the outer sheath of the cable is damaged, thus shortening the effective waterproof and flame-retardant time of the cable material, this application provides a waterproof and flame-retardant cable and its preparation method.

[0005] This application provides a waterproof and flame-retardant cable and its preparation method, which adopts the following technical solution:

[0006] A waterproof and flame-retardant cable includes: a conductive core, an outer sheath layer wrapped around the conductive core, and a filler layer filling the space between the outer sheath layer and the conductive core; wherein the filler layer is made from raw materials comprising the following parts by weight: 100-160 parts epoxy resin, 60-120 parts heptafluorodecyl cage-like polysilsesquioxane, 50-100 parts polytetrafluoroethylene, and 1-3 parts silicone powder; the outer sheath component comprises: polycarbonate cross-linked polyethylene composite.

[0007] By adopting the above technical solution, since this application uses the superhydrophobic filler component octaheptafluorodecylsiloxane, it can react with the polymer in the filler through the reactive octaheptafluorodecyl group, thereby generating chemical bonding between polymers. Each component can achieve uniform dispersion at the molecular layer and has good fusion with the epoxy resin matrix. Through its cage-like structure, it can also achieve chemical bonding between the inorganic and organic phases, solving the problem of weak interfacial bonding between the metal conductive core and the filler layer. Therefore, it plays a good fixing effect between the conductive core and the outer sheath layer. With the addition of epoxy resin with excellent flame retardant properties and polytetrafluoroethylene flame retardant insulation material, the cable can have good waterproof and flame retardant effects and self-healing ability, extending the service life of the cable.

[0008] Preferably, the cross-linked polyethylene is a chemically cross-linked polyethylene obtained by initiating a free radical reaction through high-temperature decomposition of peroxides.

[0009] Preferably, the metal surface of the conductor is further coated with an amphiphilic coating.

[0010] By adopting the above technical solution, the amphiphilic coating can provide better protection for the internal conductive core metal wires, and can also serve as an amphiphilic intermediary layer to link the conductive core and the filler, thereby enhancing the integrity between the conductive core and the sheath filler.

[0011] Preferably, the raw materials for the amphiphilic coating include: 40-60 parts of any one of sodium silane, potassium silane, and ammonium silane alkyl salts, 20-30 parts of metal alkoxide, 20-30 parts of ethanol, 10-40 parts of water, and 3-15 parts of xanthan gum.

[0012] By adopting the above technical solution, on the one hand, the mechanical properties of the conductive core are enhanced; on the other hand, the brush-anchoring effect gel coating formed by the filler components and the long-lasting release activator silane metal salt inside the coating create a strong force between the octaheptafluorodecyl cage-like polysilsesquioxane, epoxy resin, and conductive core metal coating. This allows the internal filler of the cable to be well shaped, preventing the filler from scattering and the conductive core from being exposed after the cable sheath is damaged. This endows the sheath with good self-healing ability and maintains the cable's corrosion resistance, acid and alkali resistance, waterproof and flame retardant properties, thus extending the cable's service life.

[0013] Preferably, the outer packaging layer polycarbonate cross-linked polyethylene composite is prepared by mixing cross-linked polyethylene and polycarbonate in a weight ratio of (2-7):4.

[0014] By adopting the above technical solution, the properties of cross-linked polyethylene and polycarbonate are complementary, so that the resulting composite material can meet the performance requirements of cables in terms of acid and alkali corrosion resistance, fatigue resistance, and wear resistance.

[0015] Preferably, the conductive core is composed of 2-6 strands of aluminum wire.

[0016] Preferably, the metal alkoxide is any one of magnesium aluminum ethoxide, magnesium aluminum isopropoxide, magnesium aluminum n-butoxide, and magnesium aluminum isobutoxide.

[0017] Preferably, an amphiphilic coating is applied to the metal surface of the conductive core. The specific processing method for the amphiphilic coating is as follows: first, a metal alkoxide is reacted with water in a certain solvent to prepare a sol; then, any one of sodium silane, potassium silane, and ammonium silane is added to the sol to obtain an amphiphilic sol; the amphiphilic sol is applied to the metal surface of the conductive core at a rate of 0.3-0.6 kg per meter of conductive core length; and then, the amphiphilic sol on the conductive core is thermo-cured under drying conditions to obtain the conductive core coated with the amphiphilic coating.

[0018] By adopting the above technical solution, the bonding force between the filler components and between the filler components and the metal conductive core is promoted, the filler components and the conductive core are self-shaped, and the phenomenon of filler powder scattering is avoided to a certain extent. At the same time, the coating can further protect the metal in the conductive core and enhance its mechanical properties such as wear resistance.

[0019] In summary, this application has the following beneficial effects:

[0020] 1. Because this application uses a filler component with self-healing function in combination with an amphiphilic coating technology on the surface of the conductive core metal, the metal conductor and the filler have good connectivity. The octaheptafluorodecyl cage-like polysilsesquioxane in the filler, combined with the brush-type anchoring effect of the gel coating, can be well shaped, and the phenomenon of the conductive core being exposed after the cable sheath is damaged will not occur. This gives the sheath good self-healing ability and maintains the cable's corrosion resistance, acid and alkali resistance, waterproof and flame retardant properties, thus extending the cable's service life.

[0021] 2. In this application, polycarbonate cross-linked polyethylene composite is preferably used as the outer sheath layer, which has excellent hydrophobicity and fatigue resistance. The composite material polycarbonate and cross-linked polyethylene have complementary properties, which makes the cable have excellent chemical corrosion resistance, waterproof and flame retardant properties, and fatigue flexibility. Detailed Implementation

[0022] The following detailed description of this application is provided in conjunction with the embodiments. It should be noted that: unless otherwise specified, the conditions in the following embodiments are performed under conventional conditions or conditions recommended by the manufacturer. Unless otherwise specified, the raw materials used in the following embodiments are all from commercially available sources.

[0023] Example

[0024] Example 1

[0025] A waterproof and flame-retardant cable, the preparation method of which includes the following steps:

[0026] S1. Preparation of filler layer material: 60 kg of heptafluorodecyl cage-like polysilsesquioxane is pulverized and passed through a 120-mesh sieve, mixed and dissolved with 100 kg of epoxy resin and 50 kg of polytetrafluoroethylene, and then 1 kg of silica gel powder desiccant is added and mixed evenly to obtain the filler layer material.

[0027] S2. Preparation of outer packaging material: Mix 80 kg of cross-linked polyethylene and 160 kg of polycarbonate material, heat to uniform melt and knead for 1 hour to obtain polycarbonate cross-linked polyethylene composite.

[0028] S3. Preparation of waterproof and flame-retardant cable: Extrude the filler material to the outside of the conductive core and wrap it. After it cools to room temperature and cures, wrap the outer sheath material on the outermost layer to obtain the cable.

[0029] Example 2

[0030] A waterproof and flame-retardant cable includes the following steps:

[0031] S1. Preparation of filler material: 90 kg of heptafluorodecyl cage-like polysilsesquioxane is pulverized and passed through a 120-mesh sieve, mixed and dissolved with 130 kg of epoxy resin and 75 kg of polytetrafluoroethylene, and then 2 kg of silica gel powder desiccant is added and mixed evenly to obtain the filler material.

[0032] S2. Preparation of outer packaging material: Mix 70 kg of cross-linked polyethylene and 40 kg of polycarbonate material, heat to uniform melt and knead for 1 hour to obtain polycarbonate cross-linked polyethylene composite.

[0033] S3. Preparation of waterproof and flame-retardant cable: Extrude the filler material to the outside of the conductive core and wrap it. After it cools to room temperature and cures, wrap the outer sheath material on the outermost layer to obtain the cable.

[0034] Example 3

[0035] A waterproof and flame-retardant cable, the preparation method of which includes the following steps:

[0036] S1. Preparation of filler layer material: 120 kg of heptafluorodecyl cage-like polysilsesquioxane is pulverized and passed through a 120-mesh sieve, mixed and dissolved with 160 kg of epoxy resin and 100 kg of polytetrafluoroethylene, and then 3 kg of silica gel powder desiccant is added and mixed evenly to obtain the filler layer material.

[0037] S2. Preparation of outer packaging material: Mix 80 kg of cross-linked polyethylene and 80 kg of polycarbonate material, heat to uniform melt and knead for 1 hour to obtain polycarbonate cross-linked polyethylene composite.

[0038] S3. Preparation of waterproof and flame-retardant cable: Extrude the filler material to the outside of the conductive core and wrap it. After it cools to room temperature and cures, wrap the outer sheath material on the outermost layer to obtain the cable.

[0039] Example 4

[0040] The method is carried out according to Example 1, except that step S3 further includes: firstly, coating the metal surface of the conductive core with an amphiphilic coating. The specific processing method is to mix 20 kg of magnesium aluminum butoxide, 20 kg of ethanol, 10 kg of water, and 3 kg of xanthan gum to prepare a sol; then add 20 kg of sodium silane to the sol to obtain an amphiphilic sol. The amphiphilic sol is applied to the metal surface of the conductive core at a rate of 0.4 kg per meter of conductive core length. Then, the amphiphilic sol on the conductive core is thermally cured under drying conditions to obtain a conductive core coated with an amphiphilic coating.

[0041] Example 5

[0042] The method of Example 4 was followed, except that the inorganic activator sodium silane in the sol raw material was replaced with magnesium aluminum isopropoxide in equal amounts.

[0043] Comparative Example

[0044] Comparative Example 1

[0045] The procedure was carried out according to Example 1, except that the cross-linked polyethylene component in the outer packaging material was replaced with an equal amount of polycarbonate.

[0046] Comparative Example 2

[0047] The procedure was carried out according to Example 1, except that the polycarbonate component in the outer packaging material was replaced with cross-linked polyethylene in equal amounts.

[0048] Comparative Example 3

[0049] The method of Example 1 was followed, except that the epoxy resin was replaced in equal amounts with hexafluorodecyl cage-like polysilsesquioxane.

[0050] Comparative Example 4

[0051] The method was carried out in accordance with Comparative Example 3, except that an equal amount of hexafluorodecyl cage-like polysilsesquioxane was replaced with epoxy resin.

[0052] Performance testing

[0053] 1. Comprehensive performance test

[0054] 2. Performance testing after outer packaging material damage

[0055] Detection methods

[0056] 1. Comprehensive Performance Testing: The cables prepared according to the examples and comparative examples were tested for flame retardancy, abrasion resistance, and tensile strength. For flame retardancy, HB represents the lowest flame retardancy rating in the UL94 standard, with a burning rate of less than 40 mm / min; it must extinguish before reaching the 100 mm mark. V-2: After two 10-second burning tests, the flame extinguishes within 60 seconds, and burning material can fall off. V-1: After two 10-second burning tests, the flame extinguishes within 60 seconds, and no burning material falls off. V-0: After two 10-second burning tests, the flame extinguishes within 30 seconds, and no burning material falls off. Insulation scratch resistance was tested according to JB / T 4278.19-2011 "Verification Method for Testing Instruments and Equipment for Rubber and Plastic Wires and Cables," with a test voltage of 10V. The scratching time and the magnitude of the operating current of the test specimen when scratched were recorded. Tensile strength was tested according to GB / T... The test was conducted according to 1040 "Plastics Tensile Testing Method", and the test results are shown in Table 1;

[0057] 2. Comprehensive performance test of outer sheath material damage: The outer sheath layer of the cables prepared in the example and comparative examples was damaged by making a 3mm long and 2mm deep opening per square centimeter with a sharp knife. Various indicators were tested 24 hours after the damage treatment. The test results are shown in Table 2.

[0058] Table 1

[0059]

[0060] Table 2

[0061]

[0062]

[0063] The performance test results of Examples 1 and 4 show that the cable with the amphiphilic coating has better mechanical properties, better shape retention of the filler components, and a stronger bond with the conductive core. The performance test results of Examples 1 and 5 show that the mechanical properties are improved after coating, but the shape retention force and the bond with the conductive core are not improved, resulting in a slight increase in current.

[0064] Based on the performance test results of the examples and Comparative Example 1, it can be seen that after replacing cross-linked polyethylene with polycarbonate in equal amounts, the raw material cost of the cable increases, the antioxidant performance decreases, the operating temperature range narrows, the waterproof and flame retardant performance is good, the flexibility is high, the fatigue resistance is very good, and the flame retardant rating decreases.

[0065] Based on the performance test results of Example 1 and Comparative Example 2, it can be seen that after replacing an equal amount of polycarbonate with cross-linked polyethylene, the fatigue resistance, self-lubricating wear resistance, and anti-photoaging properties of the outer packaging material decrease, the operating temperature range expands, and it has a good flame retardant effect.

[0066] Based on the performance test results of Example 1 and Comparative Example 3, it can be seen that when no epoxy resin is added, the shaping force of the filler decreases, the bonding with the conductive core decreases, the filler is slightly loose when not covered with the outer packaging material, and the current increases slightly. Based on the performance test results of Example 1 and Comparative Example 4, it can be seen that after replacing an equal amount of heptafluorodecyl cage-like polysilsesquioxane with epoxy resin, the mechanical properties decrease, the flexibility is insufficient, and the fatigue resistance is significantly reduced.

[0067] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of this application.

Claims

1. A waterproof and flame-retardant cable, characterized in that, include: The conductive core, the outer sheathing layer surrounding the conductive core, and the filler layer between the outer sheathing layer and the conductive core; The filler layer is made from the following raw materials in parts by weight: 100-160 parts epoxy resin, 60-120 parts octaheptafluorodecyl cage-like polysilsesquioxane, 50-100 parts polytetrafluoroethylene, and 1-3 parts silicone powder; the outer packaging material components include: polycarbonate cross-linked polyethylene composite, wherein the cross-linked polyethylene is chemically cross-linked polyethylene obtained by initiating a free radical reaction through high-temperature decomposition of peroxide, and the raw materials of the polycarbonate cross-linked polyethylene composite of the outer packaging layer are prepared by mixing cross-linked polyethylene and polycarbonate in a weight ratio of (2-7):

4.

2. The waterproof and flame-retardant cable according to claim 1, characterized in that: The metal surface of the conductive core is also coated with an amphiphilic coating.

3. A waterproof and flame-retardant cable according to claim 2, characterized in that: The raw materials for the amphiphilic coating include: 10-30 parts of any one of sodium silane, potassium silane, and ammonium silane alkyl salts, 20-30 parts of metal alkoxide, 20-30 parts of ethanol, 10-40 parts of water, and 3-15 parts of xanthan gum.

4. The waterproof and flame-retardant cable according to claim 1, characterized in that, The conductive core can be composed of 2-6 strands of aluminum wire.

5. A waterproof and flame-retardant cable according to claim 3, characterized in that: The metal alkoxide is any one of magnesium aluminum ethoxide, magnesium aluminum isopropoxide, magnesium aluminum n-butoxide, and magnesium aluminum isobutoxide.

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