Reinforcement for cable composite core, aluminum-based composite core, and manufacturing method

Abstract

The application relates to the technical field of composite cores, and provides a reinforcing body for a cable composite core, an aluminum-based composite core and a manufacturing method, which comprises the following: a reinforcing body framework made of high-performance fiber bundles; a metallized layer formed at the radial outer side of the reinforcing body framework, the metallized layer being made of metal nickel; and an interface anchoring layer formed between the reinforcing body framework and the metallized layer, the interface anchoring layer being made of carbon nanotubes, all the carbon nanotubes being randomly overlapped and punctured and arranged on the outer peripheral wall of the reinforcing body framework and the inner peripheral wall of the metallized layer. The application has lower manufacturing cost, can be used to directionally design the overall content of carbon fibers, and has excellent comprehensive mechanical properties of the aluminum-based composite core, and has commercial application foundation and potential.

Description

Technical Field

[0001] This invention relates to the field of composite core technology, and in particular to a reinforcement for cable composite cores, an aluminum-based composite core, and a manufacturing method thereof. Background Technology

[0002] High-performance fibers, due to their excellent mechanical properties, are widely used in lightweight structures. Carbon fiber, with its characteristics of light weight, high corrosion resistance, non-magnetic properties, high thermal conductivity, extremely low coefficient of thermal expansion, high tensile strength, and high tensile elasticity, is the primary application. Existing resin-based composite cores for overhead conductors suffer from two main drawbacks: firstly, long-term exposure to air, rain, and ultraviolet radiation, coupled with the galvanic corrosion of the high-current aluminum conductor layer, makes the composite core prone to aging, failure, and breakage; secondly, conventional metal clamping hardware and installation methods are difficult to apply directly to resin-based composite cores, requiring customized tools or modified operating methods, and are prone to cracking and failure during conductor removal, transfer, and grid installation. Using a metal matrix instead of resin matrix to create a metal-based composite core with carbon fiber effectively solves these problems while meeting lightweight requirements, making it more suitable for high-current-carrying new grid construction and upgrading of existing grids. Metal-based composite cores can utilize the advantages of conventional clamping hardware and installation methods, greatly reducing their construction costs. At the same time, metal-based composite cores themselves have a certain current transmission capacity, significantly improving current carrying efficiency. Their mechanical properties are more outstanding than those of conventional conductors, making them more easily accepted by the market. As a result, a series of studies have been conducted.

[0003] The known patent CN102260836B involves high-temperature degumming of carbon fiber surfaces followed by electroplating to obtain a copper layer. The dried copper-plated carbon fiber bundles and a fibrous metal matrix are then passed through a high-temperature heating mold with a circular cross-section. The fibrous aluminum metal matrix melts upon heating and impregnates the copper-plated carbon fiber bundles with its own wettability. After cooling, the bundles are collected to obtain a copper-plated carbon fiber-reinforced aluminum-based composite core. This invention only uses thermally oxidized carbon fibers, limiting the number of mechanical bonding points and the degree of functional group activation. The reactivity between the fiber surface functional groups and copper ions is weak. Prolonged high-temperature treatment to obtain higher activity can easily deepen the damage thickness of the carbon fiber skeleton surface, resulting in poor retention of the fiber's mechanical properties. Furthermore, the electroplating method is greatly affected by fiber dispersion and conductivity, easily producing a "black core" phenomenon at the fiber bundle axis, manifested as misalignment and uneven thickness of the metallization layer on the monofilaments, and difficulty in plating metal onto the monofilaments at the multifilament axis. Furthermore, the molten metal matrix cannot completely penetrate the fiber by its own wettability alone, and gaps are easily left between the fiber and metal interface. The pores formed after cooling pose a potential failure hazard for the normal use of the composite core.

[0004] The known patent CN104871256A describes a process where nanoparticles are deposited on the surface of alumina fibers, followed by a vacuum impregnation process to combine the reinforcement with a molten aluminum matrix to obtain an alumina fiber-reinforced aluminum matrix composite core. However, this invention fails to consider the interfacial bonding between the alumina fibers and the metal matrix. The alumina-loaded nanoparticles deposited on the fiber surface are not further treated, resulting in poor wettability between the alumina and molten aluminum interface. This interface is prone to chemical reactions at high temperatures, forming a brittle transition layer, significantly reducing the bonding effect between the fiber and the metal. Consequently, the molten aluminum in this process does not fully impregnate the alumina fiber bundles, and the pores on the fiber filament surface and the metal interface easily lead to delamination, debonding, and cracking during long-term use of the composite core. Furthermore, this invention is limited by the high cost of imported high-performance alumina fibers, insufficient wetting effect between the fiber and the metal matrix, difficulty in controlling fiber dispersion uniformity, and the inability to achieve excellent mechanical properties with low fiber content. The poor balance between lightweight and high performance severely hinders the commercialization and application of this composite core.

[0005] The known patent CN112885518A involves first coating a high-temperature resistant layer onto the surface of alumina fibers, then depositing a metallized layer on the surface using magnetron sputtering or chemical vapor deposition, and finally preparing an aluminum-based composite core using a vacuum impregnation process. The high-temperature resistant coating has mostly inert functional groups, making it resistant to oxidation and denaturation, and its dense, wear-resistant surface structure. However, this type of high-temperature resistant coating inhibits bonding with the metal interface to some extent, and a weak bond between the fiber and the metal interface will become a key factor in the subsequent failure of the composite core. Furthermore, magnetron sputtering and chemical vapor deposition metallization processes often occur within closed cavities, making them more suitable for intermittent preparation of discontinuous small- to medium-sized products, and difficult to meet the requirements for preparing long, continuous, stable, and uniform metallized fibers.

[0006] In summary, the main technical challenges in preparing metal matrix composite cores lie in the interfacial bonding effect between the high-temperature molten metal and the fiber, the uniformity of fiber dispersion, and the maximum retention of the fiber's intrinsic mechanical properties. Meanwhile, finding cost-effective fiber reinforcements is the cornerstone for the commercialization of metal matrix composite cores. Carbon fiber has seen faster domestic production than alumina fiber, is highly competitive in price, and boasts superior overall performance. However, if the carbon fiber surface comes into direct contact with high-temperature molten metal, a chemical reaction occurs, generating metal compounds such as carbon-aluminum compounds. These substances easily embrittle the fiber surface and result in low interfacial bonding with the metal, significantly weakening the interfacial bond between the fiber skeleton and the metallized layer. Summary of the Invention

[0007] In view of the shortcomings of the prior art described above, the technical problem to be solved by the present invention is to provide a reinforcing body for cable composite cores, an aluminum-based composite core, and a manufacturing method thereof. The present invention has lower manufacturing costs, allows for the directional design of the overall carbon fiber content, and provides better comprehensive mechanical properties of the aluminum-based composite core, while also having the basis and potential for commercial application.

[0008] To address the aforementioned technical problems, the present invention provides a reinforcing body for a cable composite core, comprising:

[0009] The reinforcing skeleton is made of high-performance fiber bundles;

[0010] Metallization layer, formed on the radially outer side of the reinforcing skeleton;

[0011] The junction anchoring layer is formed between the reinforcing skeleton and the metallization layer. The junction anchoring layer is made of carbon nanotubes, all of which are randomly overlapped and punctured on the outer peripheral wall of the reinforcing skeleton and the inner peripheral wall of the metallization layer.

[0012] The present invention also provides an aluminum-based composite core, comprising:

[0013] The substrate is made of metallic aluminum or an aluminum alloy;

[0014] The cable composite core reinforcement is formed inside the matrix;

[0015] The encapsulation and constraint layer is formed on the outer peripheral wall of the substrate and is made of aluminum or an aluminum alloy.

[0016] The present invention also provides a method for manufacturing the aluminum-based composite core, comprising the following steps:

[0017] The molding steps for the reinforcement of cable composite core are as follows: a reinforcement skeleton is made by using high-performance fiber bundles, carbon nanotubes are covered on the outer surface of the reinforcement skeleton to form a junction anchoring layer, and metal materials are attached to the junction anchoring layer to form a metallization layer.

[0018] The molding process for cable composite core reinforcement: passing the cable composite core reinforcement through the molding die;

[0019] The molding steps of the composite core are as follows: molten aluminum liquid or aluminum alloy liquid is injected into the molding mold. The aluminum liquid or aluminum alloy liquid fills the gaps between the fiber monofilaments in the reinforcement of the adjacent multi-strand cable composite core and the cavity of the molding mold by means of its own wettability with the metallization layer. The inert gas in the molding mold is discharged to form the composite core.

[0020] The encapsulation and constraint layer encapsulation process is as follows: When the composite core is cooled and formed to a preset diameter, a high-temperature soft encapsulation and constraint layer is encapsulated on the outer surface of the composite core. After a preset cooling time, an aluminum-based composite core is formed.

[0021] Preferably, the molding step of the cable composite core reinforcement further includes: thermal oxidation treatment of the reinforcement skeleton, heating and oxidizing the slurry on the outer surface of the reinforcement skeleton in an air environment, degreasing with ethanol, washing with deionized water and drying; wherein the heating temperature is 300-700℃ and the heating time is 10-40min.

[0022] Preferably, in the molding step of the cable composite core reinforcement, the thickness of the interface anchoring layer does not exceed 60% of the thickness of the metallization layer.

[0023] Preferably, in the molding step of the cable composite core reinforcement, the thickness of the interface anchoring layer is 50-250 nm.

[0024] Preferably, the forming step of the cable composite core reinforcement further includes: using a plasma treatment process to treat the high-performance fiber bundle coated with carbon nanotubes in a space filled with oxygen, nitrogen and nano-metal particles, so that mechanical riveting sites and active functional groups are generated on the rough surface of the high-performance fiber bundle, and a predetermined number of nano-metal particles are pre-attached on the rough surface of the high-performance fiber bundle as a reaction catalyst for metal reduction deposition; wherein, the power of the plasma treatment process is 100-400w and the treatment time is 1-10min.

[0025] Preferably, the forming step of the cable composite core reinforcement further includes: chemically plating the surface-treated high-performance fiber bundles with metal materials in a metal main salt solution, and washing and drying them with deionized water after plating.

[0026] Preferably, the molding step of the composite core further includes: injecting molten aluminum liquid or aluminum alloy liquid into the cavity of the molding mold by means of positive pressure assistance of inert gas; the aluminum liquid or aluminum alloy liquid rapidly wets and penetrates the high-performance fiber bundles that have been plated with metal materials under high pressure and fills the cavity; after cooling and stretching, the composite core is collected.

[0027] Preferably, in the wrapping step of the wrapping constraint layer, the thickness of the wrapping constraint layer is 0.1-3.0 mm.

[0028] As described above, the cable composite core reinforcement, aluminum-based composite core, and manufacturing method of the present invention have the following beneficial effects:

[0029] In the cable composite core reinforcement of the present invention, the carbon nanotubes in the interfacial anchoring layer pierce between the high-performance fiber bundle and the metallization layer mainly because the surface roughness of the carbon fiber material itself is much larger than the size of the carbon nanotubes. When the interfacial anchoring layer is formed on the surface of the high-performance fiber bundle, the surface thickness of the high-performance fiber bundle will be slightly reduced. After the metal material penetrates into the surface of the high-performance fiber bundle, the carbon nanotubes piercing the surface of the high-performance fiber bundle and the metallization layer anchor the high-performance fiber bundle and the metallization layer together like nails, which greatly improves the interfacial bonding effect between the reinforcement skeleton and the metallization layer.

[0030] In the aluminum-based composite core of this invention, the matrix and the cable composite core are firmly bonded by the reinforcement, the fibers are uniformly dispersed, and the overall mechanical properties are excellent. It can be installed using conventional clamping hardware and installation methods. This technology solves problems in existing technologies such as the difficulty in bonding fibers to the metal matrix due to heat corrosion failure, uneven fiber dispersion, high cost of alumina fibers, difficulty in achieving continuous metallization, and the difficulty in balancing weight reduction, performance, cost, and commercialization.

[0031] The aluminum-based composite core obtained by the manufacturing method of this invention is beneficial to improving the mechanical properties, production efficiency and service life of the aluminum-based composite core, and is especially suitable for use in overhead conductors. Attached Figure Description

[0032] Figure 1 The diagram shown is a cross-sectional schematic of the cable composite core reinforcement of the present invention.

[0033] Figure 2 The image shown is a magnified micrograph of the interface anchoring layer.

[0034] Figure 3 The diagram shown is a cross-sectional schematic of the aluminum-based composite core of the present invention.

[0035] Component designation explanation

[0036] 1. Reinforced skeleton

[0037] 2 Metallization layer

[0038] 3. Matrix

[0039] 4. Wrapping Constraint Layer

[0040] 5. Intersection Anchoring Layer Detailed Implementation

[0041] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0042] It should be understood that the structures, proportions, sizes, etc., depicted in the accompanying drawings of this specification are merely for illustrative purposes to aid those skilled in the art and are not intended to limit the scope of the invention. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and purpose of the invention, should still fall within the scope of the technical content disclosed in this invention. Furthermore, the terms such as "upper," "lower," "left," "right," "middle," and "one" used in this specification are merely for clarity and are not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention's implementation.

[0043] The purpose of this invention is to address the shortcomings of the aforementioned technologies by proposing a metal matrix composite core with a metallized carbon fiber reinforced structure and its manufacturing method, which features a reliable interface bonding, stable comprehensive mechanical properties, increased electrical current carrying capacity, low construction cost, broad compatibility with inorganic fibers, and commercial potential.

[0044] like Figure 1 and Figure 2 As shown, the present invention provides a reinforcing body for a cable composite core, comprising:

[0045] The reinforcing skeleton 1 is made of high-performance fiber bundles; the high-performance fibers may include, for example, carbon fiber, silicon carbide fiber, ultra-strong glass fiber, basalt fiber, polyimide fiber, ultra-high molecular weight polyethylene fiber, etc.

[0046] Metallization layer 2 is formed on the radial outer side of the reinforcing skeleton 1. The material used for the metallization layer can be mainstream power transmission conductor metals, such as copper, aluminum, tin, nickel, chromium, zirconium, silver, gold, etc.; in some embodiments, the metallization layer 2 is often made of metallic nickel.

[0047] The junction anchoring layer 5 is formed between the reinforcing skeleton 1 and the metallization layer 2. The junction anchoring layer 5 is made of carbon nanotubes, and all carbon nanotubes are randomly overlapped and punctured on the outer peripheral wall of the reinforcing skeleton 1 and the inner peripheral wall of the metallization layer 2.

[0048] In the cable composite core reinforcement of the present invention, the interfacial bonding between carbon fiber and metals such as copper, aluminum, tin, nickel, silver, and gold is more reliable than that with nickel. The reinforcement skeleton 1 is made of high-performance fiber bundles and the metallization layer 2 is made of metallic nickel. The reason why the carbon nanotubes of the interfacial anchoring layer 5 pierce between the high-performance fiber bundles and the metallization layer 2 (i.e., the nickel layer) is mainly because the surface roughness of the carbon fiber material itself is much larger than the size of the carbon nanotubes. When the interfacial anchoring layer 5 (i.e., the carbon nanotube layer) is formed on the surface of the high-performance fiber bundle, the surface thickness of the high-performance fiber bundle will be slightly reduced. After the metal material penetrates into the surface of the high-performance fiber bundle, the carbon nanotubes that pierce the surface of the high-performance fiber bundle and the nickel layer anchor the high-performance fiber bundle and the nickel layer together like nails, which greatly improves the interfacial bonding effect between the reinforcement skeleton 1 and the metallization layer 2.

[0049] The carbon nanotubes are arranged in a random overlapping distribution. Figure 1 The use of continuous wavy lines is for illustrative purposes only and does not represent a specific structure. Generally, carbon nanotubes are about 10 micrometers long.

[0050] Therefore, the cable composite core reinforcement of the present invention can greatly improve the bonding strength between the reinforcement skeleton 1 and the metallization layer 2.

[0051] like Figure 3 As shown, the present invention also provides an aluminum-based composite core, comprising:

[0052] Substrate 3, which is made of metallic aluminum or an aluminum alloy;

[0053] The multi-strand cable composite core reinforcement is formed inside the base 3;

[0054] Encapsulation and constraint layer 4 is formed on the outer peripheral wall of the substrate 3, and encapsulation and constraint layer 4 is made of aluminum or aluminum alloy.

[0055] In the aluminum-based composite core of this invention, the matrix 3 and all the cable composite core reinforcements together constitute the primary composite core. When the total volume content of the high-performance fiber bundles is high, the carbon fibers will approach the surface contour of the matrix 3 infinitely. At this time, the thickness of the matrix 3 covering the carbon fibers is extremely low, and it is even very likely that the carbon fibers will be missing or exposed. In addition, the high-performance fiber bundles of all the cable composite core reinforcements are arranged in parallel along the axis without any other direction distribution, which makes the mechanical properties of the aluminum-based composite core poor in directions other than the carbon fiber axis. Especially when installing clamping hardware, being subjected to external friction, compression, bending, and torsion, it is easy to be damaged and fail. Based on this, the wrapping constraint layer 4 provides a certain uniform constraint force along the radial direction of the matrix 3, which plays the role of protecting the primary composite core. At the same time, it can also improve the radial compression resistance, axial bending resistance, and resistance to galvanic corrosion, rainwater acid corrosion, and ultraviolet aging, extend the service life of the aluminum-based composite core, and minimize the risks of fiber damage, hardware clamping failure, and installation friction cracking failure.

[0056] Figure 3 To highlight the specific structural features of the cable composite core reinforcement, only an illustration is provided. The number of cable composite core reinforcements contained in the wrapping and restraining layer 4 is determined by the actual number of carbon fiber bundles (K) used, with the number of monofilaments in a single carbon fiber bundle ranging from hundreds of thousands.

[0057] Therefore, in the aluminum-based composite core of the present invention, the matrix 3 and the cable composite core are firmly bonded by the reinforcement, the fibers are uniformly dispersed, and the overall mechanical properties are excellent. Conventional clamping fittings and installation methods can be used for construction. This technology can solve problems in existing technologies such as the difficulty in bonding fibers to the metal matrix due to heat corrosion failure, uneven fiber dispersion, high cost of alumina fibers, difficulty in achieving continuous metallization, and the difficulty in balancing weight reduction, performance, cost, and commercialization.

[0058] Metallized carbon fiber reinforced aluminum-based composite core, with carbon fiber content reaching 40-70%, the matrix 3 is tightly and reliably bonded to the nickel layer of the cable composite core reinforcement. At the same time, the nickel layer has a significantly improved interfacial bonding force with the reinforcement skeleton due to the interfacial reinforcement and chemical bonding of carbon nanotubes. Combined with the restraining and protective function of the outermost wrapping restraining layer 4 of the aluminum-based composite core, the comprehensive mechanical properties of the aluminum-based composite core are greatly improved, such as compression resistance, bending resistance, torsion resistance, shear resistance, and impact resistance.

[0059] Therefore, compared with existing alumina fiber aluminum-based reinforced composite cores, the aluminum-based composite core of the present invention has a lower manufacturing cost, allows for the directional design of the overall carbon fiber content, and exhibits better comprehensive mechanical properties, while also possessing the foundation and potential for commercial application.

[0060] The present invention also provides a method for manufacturing the aluminum-based composite core, comprising the following steps:

[0061] The molding steps of the reinforcement for cable composite core are as follows: a reinforcement skeleton 1 is made by using high-performance fiber bundles, carbon nanotubes are covered on the outer surface of the reinforcement skeleton 1 to form an interfacial anchoring layer 5, and metallic nickel is attached to the interfacial anchoring layer 5 to form a metallization layer 2.

[0062] The molding process for cable composite core reinforcement: passing the cable composite core reinforcement through the molding die;

[0063] The molding steps of the composite core are as follows: Molten aluminum liquid or aluminum alloy liquid is injected into the molding mold. The aluminum liquid or aluminum alloy liquid fills the gaps between the fiber monofilaments in the adjacent multi-strand cable composite core reinforcement and the cavity of the molding mold by means of its own wettability with the metallization layer 2. The inert gas in the molding mold is discharged to form the composite core.

[0064] The encapsulation and constraint layer 4 encapsulation step: When the composite core is cooled and formed to a preset diameter, a high-temperature soft encapsulation and constraint layer 4 is encapsulated on the outer surface of the composite core, and an aluminum-based composite core is formed after a preset cooling time.

[0065] The manufacturing method of the present invention has the following technical effects:

[0066] First, the carbon fiber surface is coated with a layer of carbon nanotubes. The carbon nanotube layer can effectively improve the interfacial bonding between the metal and the carbon fiber skeleton through the advantages of its spatial arrangement structure. This is another physical reinforcement method in addition to molecular bonding and intermolecular attraction.

[0067] Secondly, plasma technology is used to replace conventional chemical modification for fiber surface pretreatment. During plasma treatment, oxygen, nitrogen, and nickel-containing particle clusters are added, which generates a large number of mechanical bonding sites and active functional groups on the surface of the partially exposed carbon fiber skeleton and carbon nanotubes. At the same time, some nickel particles can be pre-formed on the carbon fiber surface as a catalyst for the subsequent rapid formation of the metallic nickel layer.

[0068] Thirdly, using electroless plating to coat a nickel layer can achieve relatively stable and uniform metallization of continuous fibers. With the support of plasma treatment, electroless plating achieves more uniform metallization at both the single filament diameter and fiber bundle levels, effectively controlling the "black core" phenomenon. Furthermore, electroless plating is more conducive to the preparation and industrialization of continuous metallized fibers.

[0069] Fourthly, the aluminum-based composite core is prepared using an inert gas positive pressure injection melting matrix impregnation process. With the aid of positive pressure, molten aluminum is injected into a closed cavity and rapidly impregnates and penetrates the nickel-plated high-performance fiber bundles to fill the cavity. This is a significant improvement over the ability of the molten metal to bind fibers under normal pressure by relying solely on its own impregnation fluidity. This process can not only improve production efficiency, but also significantly reduce the number of internal pore defects in the aluminum-based composite core, which is beneficial to improving the mechanical properties of the composite core.

[0070] Fifthly, an aluminum layer is further coated on the surface of the composite core, which is a clever design that distinguishes it from conventional composite core structures. The aluminum coating provides a more uniform constraint force along the radial direction of the composite core and can be integrated with the impregnated matrix material. This not only protects the surface of the composite core from structural damage, aging, corrosion and other damage, but also provides the composite core with comprehensive mechanical properties such as radial compression resistance, axial bending resistance and torsion resistance.

[0071] Sixthly, in addition to the application of carbon fiber, this manufacturing method expands the application range of inorganic fibers such as silicon carbide fiber, boron fiber, basalt fiber, and quartz fiber in metal matrix composites through surface metallization treatment, and provides a new research direction for the application of organic fibers such as ultra-high molecular weight polyethylene, polyimide, and aramid to metal matrix composite cores.

[0072] Therefore, the aluminum-based composite core obtained by the manufacturing method of the present invention is beneficial to improving the mechanical properties, production efficiency and service life of the aluminum-based composite core, and is especially suitable for use in overhead conductors.

[0073] To further improve the bonding ability between the reinforcing skeleton 1 and the metallization layer 2, the forming step of the cable composite core reinforcement further includes: performing a thermal oxidation treatment on the reinforcing skeleton 1, heating and oxidizing the slurry on the outer surface of the reinforcing skeleton 1 in an air environment, degreasing with ethanol, washing with deionized water and drying; wherein the heating temperature is 300-700℃ and the heating time is 10-40min; the higher the temperature, the shorter the time can be.

[0074] In order to enable the metallization layer 2 to be directly bonded to a portion of the outer surface of the reinforcing skeleton 1, the thickness of the interface anchoring layer 5 shall not exceed 60% of the thickness of the metallization layer 2 during the molding step of the reinforcing body for the cable composite core.

[0075] In order to improve the mutual anchoring effect of the junction anchoring layer 5 on the reinforcing skeleton 1 and the metallization layer 2, the thickness of the junction anchoring layer 5 is 50-250 nm in the molding step of the cable composite core reinforcement.

[0076] The forming step of the cable composite core reinforcement further includes: using a plasma treatment process to treat high-performance fiber bundles coated with carbon nanotubes in a space filled with oxygen, nitrogen, and nano-metal particles (e.g., nano-nickel particles). This process generates mechanical bonding sites and active functional groups on the rough surface of the high-performance fiber bundles. Simultaneously, a predetermined number of nano-metal particles are pre-attached to the rough surface of the high-performance fiber bundles to act as a reaction catalyst for metal reduction deposition. The plasma treatment process has a power of 100-400W and a treatment time of 1-10 minutes. This operation facilitates the rapid and sustained initiation of the chemical plating reaction.

[0077] To improve the adhesion of the metallization layer 2, the forming step of the cable composite core reinforcement further includes: chemically plating a metal material (e.g., nickel) onto the surface-treated high-performance fiber bundles in a metal main salt solution; after plating, washing with deionized water and drying. The temperature of the chemical plating solution is controlled by a heating device, and the pH value and metal main salt content of the plating solution are identified by a concentration sensor. A replenishment device replenishes each component according to consumption to ensure that the content of each component in the plating solution is basically stable and the pH value of the reaction environment is balanced within the optimal range. A metal coating thickness between 0.2-1.0 μm is more suitable, and the specific thickness can be set according to requirements.

[0078] To avoid bubbles or voids in the substrate 3, the molding step of the composite core also includes: injecting molten aluminum liquid or aluminum alloy liquid into the cavity of the molding mold by positive pressure assistance of inert gas; the aluminum liquid or aluminum alloy liquid rapidly wets and penetrates the high-performance fiber bundles that have been plated with metal materials (such as nickel) under high pressure and fills the cavity; after cooling and stretching, the composite core is collected.

[0079] While ensuring the constraint effect of the wrapping constraint layer 4, the amount of material used in the wrapping constraint layer 4 is reduced. In the wrapping step of the wrapping constraint layer 4, the thickness of the wrapping constraint layer 4 is 0.1-3.0mm.

[0080] In summary, this invention offers lower manufacturing costs, allows for targeted design of the overall carbon fiber content, and results in superior comprehensive mechanical properties of the aluminum-based composite core, while also possessing the foundation and potential for commercial application. Therefore, this invention effectively overcomes the various shortcomings of existing technologies and has high industrial applicability.

[0081] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A reinforcing material for a cable composite core, characterized in that, include: The reinforcing skeleton (1) is made of high-performance fiber bundles; Metallization layer (2) is formed on the radial outer side of the reinforcing skeleton (1), and the metallization layer (2) is made of metallic nickel; The junction anchoring layer (5) is formed between the reinforcing skeleton (1) and the metallization layer (2). The junction anchoring layer (5) is made of carbon nanotubes, and all carbon nanotubes are randomly overlapped and punctured on the outer peripheral wall of the reinforcing skeleton (1) and the inner peripheral wall of the metallization layer (2).

2. An aluminum-based composite core, characterized in that, include: The substrate (3) is made of metallic aluminum or an aluminum alloy; The cable composite core reinforcement as described in claim 1 is formed inside the base (3); Encapsulation constraint layer (4) is formed on the outer peripheral wall of the substrate (3) and is made of aluminum or aluminum alloy.

3. A method for manufacturing an aluminum-based composite core as described in claim 2, characterized in that, Includes the following steps: The forming steps of the reinforcement of the cable composite core are as follows: a reinforcement skeleton (1) is made by using high-performance fiber bundles, and carbon nanotubes are covered on the outer surface of the reinforcement skeleton (1) to form an interfacial anchoring layer (5). The high-performance fiber bundles covered with carbon nanotubes are treated in a space filled with oxygen, nitrogen and nano metal particles using plasma treatment process, so that mechanical riveting points and active functional groups are generated on the rough surface of the high-performance fiber bundles. At the same time, a predetermined number of nano metal particles are pre-attached on the rough surface of the high-performance fiber bundles as a reaction catalyst for metal reduction deposition. The power of the plasma treatment process is 100-400w and the treatment time is 1-10min. The high-performance fiber bundles after surface treatment are chemically plated with metallic nickel in a metal main salt solution, so that metallic nickel is attached to the interfacial anchoring layer (5) to form a metallization layer (2). After plating, the fiber bundles are washed with deionized water and dried. The molding process for cable composite core reinforcement: passing the cable composite core reinforcement through the molding die; The molding steps of the composite core are as follows: With the positive pressure assistance of inert gas, molten aluminum liquid or aluminum alloy liquid is injected into the cavity of the molding mold. Under high pressure, the aluminum liquid or aluminum alloy liquid quickly wets and penetrates the high-performance fiber bundle that has been plated with metallic nickel, and fills the gap between the fiber monofilaments in the adjacent multi-strand cable composite core reinforcement and the cavity of the molding mold by means of its own wettability with the metallization layer (2). The inert gas in the molding mold is discharged. After cooling and stretching, the composite core is collected. The encapsulation and constraint layer (4) encapsulation steps: When the composite core is cooled and formed to a preset diameter, a high-temperature soft encapsulation and constraint layer (4) is encapsulated on the outer surface of the composite core, and an aluminum-based composite core is formed after a preset cooling time.

4. The manufacturing method according to claim 3, characterized in that: The forming steps of the cable composite core reinforcement further include: thermal oxidation treatment of the reinforcement skeleton (1), heating and oxidizing the slurry on the outer surface of the reinforcement skeleton (1) in an air environment, degreasing with ethanol, washing with deionized water and drying; wherein the heating temperature is 300-700℃ and the heating time is 10-40min.

5. The manufacturing method according to claim 3, characterized in that: In the molding step of the cable composite core reinforcement, the thickness of the interface anchoring layer (5) does not exceed 60% of the thickness of the metallization layer (2).

6. The manufacturing method according to claim 3, characterized in that: In the molding step of the cable composite core reinforcement, the thickness of the interfacial anchoring layer (5) is 50-250 nm.

7. The manufacturing method according to claim 3, characterized in that: In the wrapping step of the wrapping constraint layer (4), the thickness of the wrapping constraint layer (4) is 0.1-3.0 mm.

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