A graphene cable and method of manufacture

Abstract

The application relates to the technical field of cable production and manufacturing, and discloses a graphene cable and a manufacturing method, which comprises a wire core, the wire core is wrapped with an insulation layer, a shielding layer and a protective layer in sequence from outside to inside, a graphene layer is further arranged between the shielding layer and the insulation layer, and the graphene layer is formed by coating graphene powder on the surface of the insulation layer; after the insulation layer is wrapped on the wire core, the graphene powder is input into a spraying device, and the graphene powder is uniformly sprayed on the periphery of the insulation layer of the wire core to form the graphene layer in the process that the cable wire core gradually slides. The application has the beneficial effects of enhancing the anti-electromagnetic interference performance of the cable, improving the durability of the cable, effectively improving the production and processing efficiency of the graphene cable, and reducing the production cost.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing technology, specifically to a graphene cable and its manufacturing method. Background Technology

[0002] With the advancement of science and technology and the improvement of people's living standards, electricity is becoming increasingly closely related to our lives. For example, smart home products have gradually become popular among the general public. In the production and use of electrical products, wires and cables are one of the essential supporting products, playing an important role in transmitting electricity, transmitting information, and realizing electromagnetic energy conversion. Wires and cables are generally composed of four basic parts: conductor, shielding layer, insulation layer, and protective layer.

[0003] Currently, the material for power cable shielding is mainly made by uniformly dispersing conductive carbon black in polymers. However, due to the poor conductivity and difficulty in dispersing carbon black, its volume resistivity is relatively high. Adding a large amount of carbon black will reduce the mechanical properties of the polymer matrix, and it is easy to generate tip discharge under high voltage electric field conditions, leading to material breakdown. Therefore, it is not effective in homogenizing the electric field for cable shielding.

[0004] In the manufacturing process of some cables, no direct intervention is taken for such problems. At most, rubber is used for the outer protective layer. However, since rubber is easily corroded and aged, the durability and corrosion resistance of the outer protective layer of the cable are greatly reduced, which directly affects the performance and service life of the power cable product. Summary of the Invention

[0005] The present invention aims to provide a graphene cable and a manufacturing method thereof to improve the electromagnetic interference resistance of the cable.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a graphene cable, comprising a core, an insulation layer, a shielding layer and a protective layer sequentially wrapped around the core, wherein a graphene layer is further provided between the shielding layer and the insulation layer, and the graphene layer is formed by coating graphene powder onto the surface of the insulation layer.

[0007] The principle and advantages of this solution are as follows: In practical applications, during the conventional cable manufacturing process, a layer of graphene powder is added between several layers of the cable core. Because graphene possesses electrical conductivity, electrothermal properties, and electromagnetic radiation shielding capabilities, the cable's electromagnetic radiation shielding performance is significantly improved. This prevents electromagnetic radiation waves from penetrating the cable surface, effectively avoiding harm to people indoors and increasing cable safety. Compared to existing technologies, this solution's advantages lie in its significantly enhanced electromagnetic radiation resistance through the graphene layer, as well as improved conductivity and heat dissipation. Combined with other layers, such as shielding and protective layers, the overall tensile strength and flexibility of the cable are effectively enhanced, improving its durability in various environments, especially in the field.

[0008] Preferably, as an improvement, the graphene layer is formed by uniformly coating graphene powder around the outer periphery of the insulating layer.

[0009] This solution also provides a method for manufacturing graphene cables, including the following steps: Select the cable cores and wrap a predetermined number of cores together with insulating material to form an insulation layer; Graphene powder is fed into a spraying device, and as the cable core gradually slides, the graphene powder is evenly sprayed onto the outer edge of the insulation layer of the core to form a graphene layer. Finally, a shielding layer and a protective layer are sequentially wrapped around the outside of the graphene layer.

[0010] Preferably, as an improvement, the spraying device has a through-hole spray nozzle, and the outer side of the spraying device has a feed interface communicating with the spray nozzle. The inner wall of the spray nozzle also has an annular groove.

[0011] This spraying device can quickly and evenly coat cables with graphene powder, thereby rapidly forming a graphene layer and enhancing the cable's electromagnetic interference resistance.

[0012] Preferably, as an improvement, the diameter of the groove opening gradually decreases from the outside of the spraying device inward.

[0013] By changing the diameter of the groove, making the inside of the groove larger and the opening smaller, a negative pressure can be formed in the annular groove, generating a stronger impact force, which in turn drives the graphene powder to be sprayed onto the cable quickly, improving efficiency.

[0014] Preferably, as an improvement, the sidewalls and bottom wall of the groove are connected by an arc.

[0015] The curved design allows for smoother airflow, enabling the graphene powder to be sprayed quickly.

[0016] Preferably, as an improvement, the graphene powder has a particle size of 15-200 nanometers.

[0017] Preferably, as an improvement, a layer of metal braided mesh is provided between the insulation layer and the protective layer.

[0018] By adding a metal braided mesh, not only can an electrostatic shielding layer be formed to protect the cable, but it can also enhance the cable's flexibility and strength.

[0019] Preferably, as an improvement, the metal woven mesh is an aluminum woven mesh or a silver woven mesh.

[0020] Preferably, as an improvement, when using a spraying device to spray graphene powder, when the cable just begins to enter the spraying device, the speed of the graphene powder is controlled to gradually increase from small to large, and after maintaining the maximum spraying speed for a certain period of time, the original spraying direction of the graphene powder is changed and spraying continues for a certain period of time, and then the spraying direction is reversed in a cycle to spray graphene powder. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the cable composition of a graphene cable according to a first embodiment of the present invention.

[0022] Figure 2 This is a schematic flowchart of an embodiment of a graphene cable manufacturing method according to the present invention.

[0023] Figure 3 This is a schematic diagram of a spraying device according to an embodiment of a graphene cable manufacturing method of the present invention.

[0024] Figure 4 This is a schematic diagram of the inner wall of the annular groove in an embodiment of a graphene cable manufacturing method of the present invention. Detailed Implementation

[0025] The following detailed description illustrates the specific implementation method: The markings in the accompanying drawings include: wire core 1, insulation layer 2, shielding layer 3, protective layer 4, graphene layer 5, spraying device 6, spraying nozzle 7, feed interface 8, and annular groove 9. Example

[0026] This embodiment is basically as shown in the appendix. Figure 1 As shown: A graphene cable includes a core 1, with an insulation layer 2, a shielding layer 3, and a protective layer 4 sequentially wrapped around the core 1. A graphene layer 5 is also provided between the shielding layer 3 and the insulation layer 2.

[0027] Specifically, the graphene layer 5 is formed by uniformly coating graphene powder onto the periphery of the insulating layer 2.

[0028] As attached Figure 2 As shown, this solution also provides a method for manufacturing graphene cables, including the following steps: Select the core 1 of the cable and wrap a predetermined number of core 1 together with insulating material to form an insulation layer 2; Graphene powder is fed into the spraying device 6, and as the cable core 1 gradually slides, the graphene powder is evenly sprayed onto the outer periphery of the insulation layer 2 of the core 1 to form a graphene layer 5. Finally, a shielding layer 3 and a protective layer 4 are sequentially wrapped around the outside of the graphene layer 5.

[0029] The cable's conductor 1 consists of three copper conductors 1, each of which is surrounded by an insulation layer 2 using an injection molding machine. This insulation layer provides protection and prevents short circuits caused by connections with other conductors 1. During the fabrication of the copper conductors 1, the three conductors 1 are first joined together, and then an insulating plastic layer is wrapped around them using an injection molding machine. The manufacturing of subsequent layers is then completed.

[0030] As attached Figure 3 As shown, the aforementioned spraying device 6 has a circular spray nozzle 7 extending through it. An inlet 8, communicating with the spray nozzle, is installed on the outside of the spraying device to facilitate the feeding of graphene powder for spraying. Simultaneously, the spraying device also has an outlet corresponding to the inlet 8, allowing the graphene powder to form a flow loop. Furthermore, the inner wall of the spray nozzle 7 has an annular groove, as shown in the attached diagram. Figure 4 As shown, the diameter of the annular groove opening gradually decreases from the outside to the inside of the spraying device, and the sidewall and bottom wall of the groove are connected by an arc, so the inner wall of the groove is arc-shaped. By setting the arc-shaped inner wall, the friction and resistance of the graphene powder can be reduced, making the graphene powder easier to flow and thus accelerating its adhesion to the insulating layer.

[0031] Due to the manufacturing process characteristics of the core 1, after the core 1 is wrapped with the insulation layer 2, since the insulation layer 2 is made using a continuous injection molding process, the insulation layer 2 has not yet solidified and stabilized immediately after wrapping. At this time, the core 1 with the insulation layer 2 is passed through the spraying device 6, and graphene powder is evenly sprayed onto the surface of the insulation layer 2. This is equivalent to the insulation layer 2 passing through a graphene brush, thereby forming a graphene layer 5 around the insulation layer 2, which significantly improves the cable's electromagnetic radiation resistance.

[0032] The graphene powder has a particle size of 15-200 nanometers, which not only ensures the convenience of graphene powder spraying, but also ensures the overall effect of the graphene layer 5 formed after spraying, and improves the electromagnetic radiation protection performance of the cable.

[0033] On the other hand, a metal braided mesh is also provided between the insulation layer 2 and the protective layer 4. It is made of aluminum or silver and uses the metal braided mesh to form an electrostatic shielding effect. This not only protects the internal core 1 of the cable, but also improves the strength of the cable and prevents the cable from deforming or being damaged under long-term use or repeated bending.

[0034] The inherent properties of graphene determine the characteristics of the cable. Furthermore, graphene's stable performance and low susceptibility to interference allow it to effectively conduct heat during prolonged cable use, especially when the cable current is high and heat generation is significant, ensuring that other layers are not damaged. It also enhances the cable's electromagnetic radiation protection performance. During electromagnetic wave transmission, graphene's high conductivity allows electromagnetic waves to be rapidly absorbed and converted into heat energy. Simultaneously, graphene's structure prevents electromagnetic waves from penetrating, effectively reducing the intensity of electromagnetic radiation and minimizing the adverse effects of live cables on the human body.

[0035] Adding a graphene layer 5 to a cable can enhance its conductivity, improve its high-temperature resistance and mechanical strength, and also improve its electromagnetic interference resistance. Therefore, the graphene layer 5 can serve as an interlayer between the insulation layer 2 and the shielding layer 3 of the cable to improve the overall performance of the cable.

[0036] The specific implementation process of this embodiment is as follows: The first step is to select the cable core 1, wrap an insulation layer 2 around the outside of each single core 1, and then select a predetermined number of core 1 according to actual needs, and wrap multiple single core 1 together with the insulation layer 2 to fix and insulate them.

[0037] The second step involves using a continuous injection molding process to wrap the core 1 with the insulation layer 2, then passing the core 1 through the spray nozzle 7 of the spraying device 6 to uniformly coat the surface of the insulation layer 2 with a layer of graphene, thereby forming the graphene layer 5.

[0038] The third step is to wrap the cable with the shielding layer 3 and the protective layer 4 after the graphene layer 5 has been sprayed.

[0039] This solution enables the formation of a graphene layer 5 inside a traditional cable, improving not only its thermal and electrical conductivity but also its electromagnetic interference resistance, thus enhancing cable safety. Furthermore, the formation process of the graphene layer 5 in this solution is very simple and convenient, unlike existing technologies which require the separate fabrication of numerous graphene fibers before wrapping them around the cable. This solution addresses the issue that after the core 1 is thermoplasticized under high temperatures, the insulation layer 2 does not immediately cool and solidify. Therefore, the core 1 is again passed through a spraying device 6, utilizing the adhesion of the insulation layer 2 to the powder, to uniformly spray graphene powder onto the outer periphery of the insulation layer 2, thereby forming a graphene layer 5 to enhance cable performance.

[0040] Therefore, this solution not only allows for the addition of a graphene layer 5 to the cable to improve its performance, but also simplifies the entire process by eliminating the need for separate graphene product preparation. This effectively improves the production efficiency of graphene cables while reducing production costs. Example

[0041] This embodiment is basically the same as Embodiment 1, except that: When using the spraying device 6 to spray graphene powder, when the cable just begins to enter the spraying device 6, the speed of the graphene powder is controlled to gradually increase from small to large. After maintaining the maximum spraying speed for a certain period of time, the spraying direction of the graphene powder is reversed and spraying continues for a certain period of time. Then, the spraying direction is reversed again to spray graphene powder in a cycle.

[0042] By controlling the spraying speed and direction of graphene powder, not only can the graphene powder in the annular groove 9 be made more uniform, but it can also make the graphene powder adhere quickly to the outer periphery of the insulation layer 2. Furthermore, by repeatedly changing the speed and direction, the graphene powder can be prevented from accumulating in the groove, thereby improving the production efficiency of graphene cables, saving the cost of graphene, and thus reducing the production cost of graphene cables.

[0043] The above descriptions are merely embodiments of the present invention. Commonly known structures and characteristics are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are aware of all existing technologies in that field, and have the ability to apply conventional experimental methods prior to that date. Those skilled in the art can, under the guidance of this application, improve and implement this solution in combination with their own capabilities. Some typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention. These should also be considered within the scope of protection of the present invention, and will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A graphene cable, characterized in that: The device includes a wire core, which is surrounded by an insulation layer, a shielding layer, and a protective layer in sequence. A graphene layer is also provided between the shielding layer and the insulation layer. The graphene layer is formed by coating graphene powder onto the surface of the insulation layer. The graphene cable is manufactured by the following method: Select the cable cores and wrap a predetermined number of cores together with insulating material to form an insulation layer; Graphene powder is fed into a spraying device, and the cable core with an insulating layer slides through the spraying device. As the cable core gradually slides, the graphene powder is evenly sprayed onto the outer edge of the insulation layer of the core to form a graphene layer. Finally, a shielding layer and a protective layer are sequentially wrapped around the outside of the graphene layer; The spraying device has a spray nozzle running through it, and the outside of the spraying device has a feed port that communicates with the spray nozzle. The inner wall of the spray nozzle also has an annular groove. The diameter of the annular groove opening gradually decreases from the outside of the spraying device inwards.

2. A method for manufacturing a graphene cable, characterized in that: Includes the following steps: Select the cable cores and wrap a predetermined number of cores together with insulating material to form an insulation layer; Graphene powder is fed into a spraying device, and the cable core with an insulating layer slides through the spraying device. As the cable core gradually slides, the graphene powder is evenly sprayed onto the outer edge of the insulation layer of the core to form a graphene layer. Finally, a shielding layer and a protective layer are sequentially wrapped around the outside of the graphene layer; The spraying device has a spray nozzle running through it, and the outside of the spraying device has a feed port that communicates with the spray nozzle. The inner wall of the spray nozzle also has an annular groove. The diameter of the annular groove opening gradually decreases from the outside of the spraying device inwards.

3. The method for manufacturing a graphene cable according to claim 2, characterized in that: The sidewalls and bottom wall of the annular groove are connected by an arc.

4. The method for manufacturing a graphene cable according to claim 2, characterized in that: The graphene powder has a particle size of 15-200 nanometers.

5. A method for manufacturing a graphene cable according to claim 2, characterized in that: Between the insulation layer and the protective layer, there is also a layer of metal woven mesh.

6. A method for manufacturing a graphene cable according to claim 5, characterized in that: The metal woven mesh is an aluminum woven mesh or a silver woven mesh.

7. A method for manufacturing a graphene cable according to claim 2, characterized in that: When using a spraying device to spray graphene powder, the speed of the graphene powder is gradually increased from a small speed when the cable first enters the spraying device. After maintaining the maximum spraying speed for a certain period of time, the original spraying direction of the graphene powder is changed and spraying continues for a certain period of time. Then, the spraying direction is reversed in a cycle to spray graphene powder.

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