A method for preparing a reinforced halogen-free flame-retardant cable shell material

Abstract

The present invention discloses a method for preparing an enhanced halogen-free flame-retardant cable sheath material, which relates to the technical field of cable sheath preparation, including: obtaining a target preparation requirement of a target cable sheath; obtaining a set of excavated material preparation schemes; performing centralized screening of schemes based on the set of excavated material preparation schemes to determine a first material preparation scheme; performing preliminary mixing of raw materials according to the first material preparation scheme, and performing a primary certification, if the certification passes, obtaining a preliminary mixed material, and performing high shear mixing, performing a secondary certification, if the certification passes, obtaining a target mixed material; extruding the target mixed material from an extruder die head, cooling and solidifying, and using a pelletizer to cut the masterbatch to obtain a target halogen-free flame-retardant cable sheath material. The present invention solves the technical problem that the prior art lacks precise control of the mixing process, resulting in low performance of the prepared halogen-free flame-retardant cable sheath material, and achieves the technical effect of precise preparation of halogen-free flame-retardant cable sheath materials.

Description

Technical Field

[0001] This invention relates to the field of cable shell preparation technology, and specifically to a method for preparing a reinforced halogen-free flame-retardant cable shell material. Background Technology

[0002] With the rapid development of modern industry and cable production technology, the flame retardancy, mechanical properties, and environmental performance of cable sheath materials have become important indicators for measuring their quality. Halogen-free flame-retardant cable sheath materials have wide applications in power, telecommunications, and construction fields, especially in applications requiring high flame retardancy and environmental protection; the use of halogen-free flame-retardant materials has become an industry trend. However, in the existing preparation process of halogen-free flame-retardant cable sheath materials, there is a lack of precise control over the mixing process, which affects the overall performance of the cable sheath material. Summary of the Invention

[0003] This application provides a method for preparing a reinforced halogen-free flame-retardant cable shell material, which addresses the technical problem that the lack of precise control over the mixing process in existing technologies leads to low performance of the prepared halogen-free flame-retardant cable shell material.

[0004] In view of the above problems, this application provides a method for preparing a reinforced halogen-free flame-retardant cable shell material.

[0005] This application provides a method for preparing a reinforced halogen-free flame-retardant cable shell material, the method comprising:

[0006] The target preparation requirements for the cable shell are obtained. Based on these requirements, an internal database of shell material preparation is mined to obtain a set of material preparation schemes. Each material preparation scheme in the set includes additive addition time, halogen-free flame retardant and reinforcing material addition ratio, initial stirring time, twin-screw extruder shear force, and twin-screw extruder mixing intensity. Based on the set of material preparation schemes, a scheme is selected through centralized screening to determine the first material preparation scheme. The raw materials are initially mixed using a high-speed mixer according to the first material preparation scheme. After the stirring time meets the initial stirring time, the mixed particles are subjected to a first agglomeration certification. If the first agglomeration certification is passed, a preliminary mixed material is obtained. The preliminary mixed material is then subjected to high-shear mixing using a twin-screw extruder according to the first material preparation scheme. During the mixing process, a melt flow rate meter is used to perform a second continuous agglomeration particle certification on the flow properties of the mixed material. If the second agglomeration certification is passed, the target mixed material is obtained. The target mixed material is extruded from the extruder die to form a continuous strip material. After the strip material is cooled and solidified, it is cut into masterbatch using a pelletizer to obtain the target halogen-free flame-retardant cable shell material.

[0007] One or more technical solutions provided in this application have at least the following technical effects or advantages: This application obtains the target preparation requirements of the target cable shell; based on the preparation requirements, it mines the internal database of shell material preparation to obtain a set of material preparation schemes, wherein each material preparation scheme in the set includes additive addition time, halogen-free flame retardant and reinforcing material addition ratio, initial stirring time, twin-screw extruder shear force and twin-screw extruder mixing intensity; based on the set of material preparation schemes, it performs centralized screening of schemes to determine the first material preparation scheme; and uses a high-speed mixer to process the raw materials according to the first material preparation scheme. The materials are initially mixed. After the mixing time meets the initial mixing time requirement, the mixed particles undergo a first agglomeration certification. If the first agglomeration certification is successful, a preliminary mixed material is obtained. A twin-screw extruder is then used to perform high-shear mixing of the preliminary mixed material according to the first material preparation scheme. During the mixing process, a melt flow rate meter is used to perform a second continuous agglomeration particle certification on the flow properties of the mixed material. If the second agglomeration certification is successful, the target mixed material is obtained. The target mixed material is extruded from the extruder die to form a continuous strip material. After the strip material is cooled and solidified, a pelletizer is used to cut the masterbatch to obtain the target halogen-free flame-retardant cable shell material. This invention solves the technical problem of existing technologies lacking precise control over the mixing process, resulting in low performance of the prepared halogen-free flame-retardant cable shell material. By obtaining the preparation requirements of the target cable shell, combined with database mining, mixing process optimization, and high-shear mixing equipment, real-time control of key parameters in the material preparation process is achieved, resulting in the precise preparation of halogen-free flame-retardant cable shell material. Attached Figure Description

[0008] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0009] Figure 1 This is a schematic diagram of a method for preparing a reinforced halogen-free flame-retardant cable shell material, provided in an embodiment of this application.

[0010] Figure 2 This is a flowchart illustrating the process of determining the first material preparation scheme in a method for preparing an enhanced halogen-free flame-retardant cable shell material according to an embodiment of this application. Detailed Implementation

[0011] This application provides a method for preparing enhanced halogen-free flame-retardant cable shell materials, which addresses the technical problem of insufficient precise control over the mixing process in existing technologies, resulting in low performance of the prepared halogen-free flame-retardant cable shell materials. By obtaining the preparation requirements of the target cable shell, and combining database mining, mixing process optimization, and high-shear mixing equipment, the method achieves real-time control of key parameters in the material preparation process, thereby achieving the technical effect of precise preparation of halogen-free flame-retardant cable shell materials.

[0012] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.

[0013] It should be noted that any variation of the terms "comprising" and "having" is intended to cover non-exclusive inclusion, for example, a process, method, system, product, or server that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or modules that are not explicitly listed or that are inherent to such processes, methods, products, or devices.

[0014] like Figure 1 As shown, this application provides a method for preparing a reinforced halogen-free flame-retardant cable shell material, the method comprising:

[0015] Step S100: Obtain the target fabrication requirements for the target cable shell.

[0016] In this embodiment, the flame retardant rating of the cable is first determined based on its application scenario, and this flame retardant rating is taken as the first sub-manufacturing requirement. Next, the mechanical performance requirements of the cable shell are further clarified, including tensile strength, impact strength, and bending resistance; these mechanical performance requirements constitute the second sub-manufacturing requirement. Finally, the first and second sub-manufacturing requirements are combined to obtain the target manufacturing requirements for the target cable shell.

[0017] Furthermore, the method provided in the application embodiments also includes:

[0018] Obtain the application flame retardant rating of the target cable shell, and use the application flame retardant rating as the first sub-manufacturing requirement; obtain the required tensile strength, required impact strength and required bending performance of the target cable shell, and generate the second sub-manufacturing requirement; use the first sub-manufacturing requirement and the second sub-manufacturing requirement as the target manufacturing requirement.

[0019] In this embodiment, the flame retardant rating of the cable sheath is first determined based on industry standards or user-defined requirements. Industry standards include IEC60332 and UL94. This determined flame retardant rating is then used as the first sub-requirement for the target cable sheath. Next, based on the cable's operating environment and application requirements, the required tensile strength of the target cable sheath is obtained by consulting commonly used mechanical performance standards in the cable industry, such as GB / T2951. The required impact strength and required bending resistance, pre-defined by technical experts, are then obtained as the second sub-requirement.

[0020] Finally, the preparation requirements of the first and second sub-sub ...

[0021] Step S200: Based on the preparation requirements, perform internal database mining of shell material preparation to obtain a set of mining material preparation schemes. Each mining material preparation scheme in the set includes additive addition time, halogen-free flame retardant and reinforcing material addition ratio, initial stirring time, twin-screw extruder shear force and twin-screw extruder mixing intensity.

[0022] In this embodiment, a database retrieval tool is used to search for material preparation requirements within an internal database for shell material preparation. These requirements include flame retardancy rating, tensile strength, impact strength, and flexural strength. The internal database contains different material formulations and their corresponding production parameters. The search yields a set of suitable material preparation schemes. Each scheme includes multiple process parameters, such as additive addition time, the ratio of halogen-free flame retardant and reinforcing materials, initial mixing time, twin-screw extruder shear force, and twin-screw extruder mixing intensity.

[0023] Furthermore, in the method provided in the application embodiments, based on the aforementioned preparation requirements, internal database mining of shell material preparation is performed to obtain a set of material preparation schemes, which further includes:

[0024] Using the first and second sub-preparation requirements as indexes, data is retrieved from the internal database of shell material preparation to obtain a set of retrieved material preparation schemes. The retrieved set of material preparation schemes undergoes difference verification. If verification passes, the retrieved set of material preparation schemes is used as the set of mined material preparation schemes. If verification fails, cloud-based data mining instructions are obtained to acquire multiple cloud-based material preparation scheme sets to supplement the retrieved set of material preparation schemes, and difference verification is performed again until verification passes, thus obtaining the set of mined material preparation schemes.

[0025] In this embodiment, an internal database retrieval tool is first used to search the internal database for shell material preparation, indexed by the first and second sub-preparation requirements, respectively. The internal database stores various material formulations and corresponding production process parameters, such as additive addition time, the ratio of halogen-free flame retardants and reinforcing materials, and relevant parameters for stirring and mixing. The database indexing tool employs a reverse indexing algorithm, converting the input requirements into keywords and quickly matching them with the corresponding set of material preparation schemes to generate a searchable set of material preparation schemes.

[0026] Next, the set of retrieved material preparation schemes was evaluated for differences. Specifically, key process parameters for each scheme were extracted, including additive addition time, the proportion of halogen-free flame retardant and reinforcing material, initial mixing time, twin-screw extruder shear force, and mixing intensity. Then, the key parameters for each scheme were compared one by one. For example, the additive addition time of one scheme might be a few minutes earlier or later than another; the proportion of halogen-free flame retardant in one scheme might be higher than in others; and the shear force of the twin-screw extruder in one scheme might be greater. By comparing these differences, the diversity of these schemes under specific process conditions was assessed. After comparing each parameter, the differences between the schemes were quantitatively evaluated. The magnitude of the differences was determined by analyzing the numerical differences between each parameter. For example, if two schemes differed significantly in the proportion of halogen-free flame retardant, it indicated that they were applicable to different application scenarios. Larger differences in the parameters meant that these schemes could cope with more complex and variable process requirements and were more adaptable.

[0027] Technical experts set a difference threshold for each parameter to determine whether the differences between parameters are sufficiently large. For example, if the difference in additive addition time exceeds a certain time, or the difference in the proportion of reinforcing materials exceeds a certain percentage, it indicates that these solutions meet the requirements for difference certification. If the differences of all parameters are within the preset threshold range, the certification is passed, and the retrieved set of material preparation solutions is used as the mining set of material preparation solutions.

[0028] If the difference verification fails, it indicates that the currently retrieved solutions have only minor differences in process parameters and may not meet diverse application needs. In this case, a cloud-based data mining command is issued to retrieve more material preparation solutions from the cloud database, supplementing the material data not covered in the internal database. The set of material preparation solutions retrieved from the cloud is integrated with the previously retrieved solution set to ensure a wider range of options. After integrating the cloud data, the new solution set undergoes difference verification again, comparing parameter differences between solutions to ensure its diversity meets predetermined standards. If the verification passes, these solutions are used as the final set of mined material preparation solutions. This process, through multiple iterations and data supplementation, ensures that the final obtained material preparation solutions have sufficient diversity and applicability to meet a wide range of practical application scenarios.

[0029] Step S300: Based on the set of mining material preparation schemes, perform centralized screening of schemes to determine the first material preparation scheme.

[0030] In this embodiment, a screening space is first constructed based on a set of material preparation schemes, containing multiple screening particles, each representing a specific material preparation scheme. Then, M screening particles are randomly selected from these particles as screening start points, and the screening space is divided into M regions according to a preset iteration bandwidth. Next, the screening density of each region is calculated, and the particle with the highest density is selected as the screening head particle, with the remaining particles forming the screening tail particle set.

[0031] Then, based on the screening head particle, multiple iterations of optimization were performed until the iteration stopping condition was met, and finally a target screening particle point was determined. The mining material preparation scheme corresponding to this particle point was taken as the first material preparation scheme.

[0032] Furthermore, such as Figure 2 As shown, the method provided in the application embodiment, which involves selecting a first material preparation scheme based on the set of mining material preparation schemes, further includes:

[0033] Based on the set of excavation material preparation schemes, a screening space is constructed to obtain a centralized screening space, which includes multiple screening particle points, each corresponding to a excavation material preparation scheme. M screening particle points are randomly selected from the multiple screening particle points, and each of the M screening particle points is used as a starting point. The iteration region in the centralized screening space is divided according to a preset iteration bandwidth to obtain M screening iteration regions, where M is an integer greater than or equal to 1. The screening density is calculated by traversing the M screening iteration regions to obtain M screening densities. The screening particle point corresponding to the maximum value of the M screening densities is used as the screening head particle, and the remaining M-1 screening particle points are used as the screening tail particle set. Taking the screening head particle as the iteration direction, the screening tail particle set is iterated in the centralized screening space according to the preset iteration bandwidth. After multiple iterations until the preset iteration stopping condition is met, the target screening particle point is obtained, and the excavation material preparation scheme corresponding to the target screening particle point is used as the first material preparation scheme.

[0034] In this embodiment, a screening space is first constructed based on the set of excavation material preparation schemes. The screening space is constructed by classifying and organizing all candidate material preparation schemes. Each scheme is uniquely identified by its key parameters, such as the additive addition time, the proportion of halogen-free flame retardant and reinforcing material, the initial stirring time, the shear force of the twin-screw extruder, and the mixing intensity, forming multiple screening particle points. Each particle point represents a specific excavation material preparation scheme.

[0035] Next, M selection particle points are randomly sampled from the selection space using a random sampling method, where M is an integer greater than or equal to 1, representing the number of particle points to be selected. The selection space is then divided according to a preset iteration bandwidth, dividing all selected particle points into different selection iteration regions. The iteration bandwidth refers to the division of the selection space into several sub-regions based on parameter differences, with each region containing a set of similar particle points.

[0036] After dividing the screening region, the screening density of each region is calculated by traversing M screening iteration regions. Specifically, for each particle point within an iteration region, the screening density is calculated by the ratio of the number of particles in the region to the area of ​​the region. The particle point corresponding to the maximum screening density is selected as the screening head particle, which represents the optimal candidate solution under the current conditions. The remaining particle points are assigned to the screening tail particle set.

[0037] Next, using the selection of the head particle as the iterative direction, the selection of the tail particle set is iteratively processed within the concentrated selection space according to a preset iterative bandwidth. In each iteration, an iterative tail particle set is generated. By traversing the iterative tail particle set and calculating the selection density of each particle, an iterative tail particle selection density set is generated. Then, it is determined whether the selection density of these iterative tail particles exceeds the density value of the current selection head particle. If so, the iterative tail particle corresponding to the maximum selection density is updated as the new selection head particle, and the next round of iterative selection continues. This process continues until a preset iteration stopping condition is met. Finally, the selection head particle obtained in the last iteration is taken as the target selection particle point, and its corresponding material preparation scheme is determined as the first material preparation scheme.

[0038] Furthermore, in the method provided in the application embodiment, taking the screening head particle as the iteration direction, the screening tail particle set is iterated in the concentrated screening space according to the preset iteration bandwidth. After multiple iterations until the preset iteration stop condition is met, the target screening particle point is obtained. The mining material preparation scheme corresponding to the target screening particle point is taken as the first material preparation scheme, and the method further includes:

[0039] Using the head particle as the iteration direction, the set of tail particles is iterated in the concentrated screening space according to the preset iteration bandwidth to obtain an iterative tail particle set; the screening density is calculated by traversing the iterative tail particle set to obtain an iterative tail particle screening density set; it is determined whether there is a screening density in the iterative tail particle screening density set that is greater than that of the head particle. If so, the iterative tail particle corresponding to the maximum value in the iterative tail particle screening density set is updated as the head particle, and iterative screening continues until the preset iteration stop condition is met. The head particle obtained in the last iteration is taken as the target screening particle point.

[0040] In this embodiment, the iteration direction is taken by selecting the head particle, and the selection space is entered. The tail particle set is iterated according to the preset iteration bandwidth. During each iteration, the tail particle set is recalculated to generate an iterative tail particle set.

[0041] Next, the set of iterative tail particles is traversed, and the screening density is calculated to obtain the set of iterative tail particle screening densities. During the screening density calculation, for each iterative tail particle, the screening density is generated by comparing the number of particles within a preset range with the area of ​​that preset range. All screening densities are then integrated to obtain the set of iterative tail particle screening densities.

[0042] The set of screening densities is then compared with the current screening head particle. If the density of certain regions is found to be greater than that of the region containing the screening head particle, the particle corresponding to the maximum screening density is updated as the new screening head particle, and the next iteration continues. This iterative process continues until the iteration stopping condition is met, that is, the density change of the screening head particle between two adjacent iterations is no longer significant. Finally, the screening head particle obtained in the last iteration is taken as the target screening particle point, and its corresponding scheme is determined as the first material preparation scheme.

[0043] Furthermore, the method provided in the application embodiments also includes:

[0044] The preset iteration stopping condition is that the difference in screening density between two screening head particles obtained in two adjacent iterations is less than or equal to a preset screening density difference. In this embodiment, the preset iteration stopping condition is determined by comparing the screening densities of two screening head particles obtained in two adjacent iterations. Specifically, in each iteration, the current screening density of the screening head particle is calculated and compared with the density value of the screening head particle obtained in the previous iteration. If the difference between these two screening densities is less than or equal to the preset screening density difference, the stopping condition is met, and the iteration process ends.

[0045] Step S400: Use a high-speed mixer to perform preliminary mixing of raw materials according to the first material preparation scheme. After the stirring time meets the preliminary stirring time, perform an agglomeration certification on the mixed particles. If the agglomeration certification is passed, a preliminary mixed material is obtained.

[0046] In this embodiment, the raw materials are first fed into a high-speed mixer for preliminary mixing according to the requirements of the first material preparation scheme. This step ensures that the components are evenly distributed and achieves the desired initial mixing effect. The high-speed mixer applies shear force through high-speed rotating blades, quickly and thoroughly mixing the various materials. The core parameters in the mixing process include stirring speed, stirring temperature, and preliminary stirring time. These parameters have been set in advance in the first material preparation scheme.

[0047] Once the set initial mixing time is reached, high-speed mixing is stopped, and the focus shifts to testing the mixed particles. An agglomeration certification is then performed. First, multiple preliminary mixed particle samples are randomly sampled from the mixed particles. Next, these samples are analyzed using an optical microscope to observe particle morphology, observing whether the particles are uniformly mixed and whether agglomeration occurs. Microscopic examination generates agglomeration analysis results for multiple preliminary samples, reflecting the particle state of each sample. These results are then comprehensively analyzed to assess the particle distribution and degree of agglomeration. Based on the analysis results, a final agglomeration certification result is obtained. If the certification results indicate uniform particle size and agglomeration is controlled within acceptable limits, the agglomeration certification is passed, and the preliminary mixed material is obtained.

[0048] Furthermore, in the method provided in the application embodiment, a high-speed mixer is used to initially mix the raw materials according to the first material preparation scheme. After the mixing time meets the initial mixing time, the mixed particles are subjected to an agglomeration certification. If the agglomeration certification is passed, a preliminary mixed material is obtained. The method further includes:

[0049] Random sampling is performed on the mixed particles to obtain multiple preliminary mixed particle samples; the particle morphology of the multiple preliminary mixed particle samples is analyzed using an optical microscope to determine the agglomeration analysis results of the multiple preliminary samples; the agglomeration analysis results of the multiple preliminary samples are comprehensively analyzed, and an agglomeration certification result is obtained based on the analysis results. If the agglomeration certification result is a successful agglomeration certification, the preliminary mixed material is obtained.

[0050] In this embodiment, the mixed material is first randomly sampled from different locations using a random sampling tool to obtain multiple preliminary mixed particle samples. These samples are then fed into an optical microscope via an automated sampler for particle morphology analysis. The optical microscope automatically focuses and images the samples, capturing images of the particles at high magnification, scanning the particles, and recording data such as size, shape, and arrangement to ensure detailed information about each particle is captured. A built-in analysis module measures the particle size, shape characteristics, and distances between particles. After particle morphology analysis, aggregation analysis is performed. By analyzing the arrangement and distribution of particles, the presence of aggregation is determined. If the distance between particles is less than a preset range and the density distribution exceeds a preset density, the phenomenon is marked as aggregation. By analyzing the particle distribution density and aggregation areas in each sample, multiple preliminary sample aggregation analysis results are generated.

[0051] Subsequently, the results of the preliminary clustering analysis of multiple samples were comprehensively analyzed, summarizing the distribution density, interparticle distance, and aggregation regions of all samples to form an analysis dataset for all samples. Next, a weighted average was calculated for these summarized data. The weight of each sample was set by technical experts based on the particle distribution density or the severity of aggregation. For example, samples with more uniform particle distribution or less aggregation were assigned higher weights, while samples with larger aggregations were assigned lower weights. Through this weighted averaging process, a comprehensive value for each parameter, such as the average interparticle distance and the density of the aggregation region, was calculated.

[0052] After weighted averaging, a comprehensive analysis result is generated, representing the overall aggregation status of all samples. This result is then compared with preset aggregation certification criteria. These criteria include indicators such as particle distribution uniformity, particle spacing, and allowable aggregation region size. If the weighted average result meets these preset criteria, the material's mixing quality is deemed satisfactory and compliant with certification requirements.

[0053] Based on the weighted average results, a single agglomeration certification result is generated. If the comprehensive analysis results meet the preset standards, the single agglomeration certification is passed, indicating that the material is mixed uniformly and there is no serious agglomeration phenomenon; conversely, if the comprehensive analysis results fail to meet the standards, showing more agglomeration phenomena or uneven particle distribution, a "failed" certification result is generated.

[0054] Once a family reunification certification is approved, preliminary mixed materials are obtained.

[0055] Step S500: Using a twin-screw extruder, the preliminary mixed material is subjected to high-shear mixing according to the first material preparation scheme. During the mixing process, a melt flow rate meter is used to perform secondary continuous agglomeration particle certification on the flow properties of the mixed material. If the secondary agglomeration certification is passed, the target mixed material is obtained.

[0056] In this embodiment, a twin-screw extruder is used to perform high-shear mixing of the preliminary mixed materials according to the first material preparation scheme. The twin-screw extruder uses high shear force to fully mix the materials under high temperature and high pressure conditions to ensure further dispersion and uniform distribution of particles.

[0057] During the mixing process, a melt flow rate meter is used to continuously monitor the flow properties of the materials being mixed, acquiring real-time melt flow rate and melt volumetric flow rate sequences. Based on this flow rate data, melt viscosity is calculated to obtain a melt viscosity sequence. After the melt viscosity sequence is generated, abnormal fluctuations are identified to determine if any problems have occurred during the mixing process. If abnormal fluctuations are detected, such as a sudden change in the melt viscosity, a high-shear mixing anomaly warning command is issued, indicating the need to adjust mixing parameters or operations.

[0058] If the melt viscosity sequence shows that the material's flow properties are stable and without abnormal fluctuations, the secondary continuous agglomeration particle certification is confirmed to be successful, indicating that the mixing process has achieved the expected results, the particle distribution is uniform, and the target mixed material is finally obtained.

[0059] Furthermore, in the method provided in the application embodiment, the preliminary mixed material is subjected to high-shear mixing using a twin-screw extruder according to the first material preparation scheme. During the mixing process, a melt flow rate meter is used to perform secondary continuous agglomeration particle certification on the flow properties of the mixed material. If the secondary agglomeration certification is passed, the target mixed material is obtained. The method further includes:

[0060] The melt flow rate meter is used to continuously monitor the flow properties of the mixed material, obtaining a melt flow rate sequence and a melt volumetric flow rate sequence, wherein the melt flow rate and the melt volumetric flow rate have a one-to-one mapping relationship; based on the melt flow rate sequence and the melt volumetric flow rate sequence, the melt viscosity is calculated to obtain a melt viscosity sequence; abnormal fluctuations in the melt viscosity sequence are identified, and if abnormal fluctuations exist, a high-shear mixing abnormality warning command is issued; if no abnormal fluctuations exist, the secondary agglomeration certification is passed, and the target mixed material is obtained.

[0061] In this embodiment, the materials in the mixture are first continuously monitored by a melt flow rate meter to obtain the melt flow rate sequence of the materials. Then, the melt volume flow rate sequence is calculated based on the density of the materials. During the calculation, the melt flow rate at any time is divided by the density of the materials to obtain the corresponding melt volume flow rate. The melt volume flow rate sequence is obtained by calculation. There is a one-to-one mapping relationship between the melt flow rate sequence and the melt volume flow rate sequence.

[0062] Next, through The melt viscosity is calculated, where, Here, P is the melt viscosity, v is the pressure applied to the material, R is the volumetric flow velocity of the melt, and L is the radius and length of the capillary die. P, v, R, and L are preset values. A melt viscosity sequence is calculated. After obtaining the melt viscosity sequence, abnormal fluctuations are identified. Based on a set normal viscosity range, such as ±30%, the material's viscosity is checked to ensure it remains within a reasonable range. Sudden increases or decreases in viscosity, such as a rise from 50 Pa·s to 100 Pa·s within 1 second, or a drop to 25 Pa·s, are identified as abnormal fluctuations. If abnormal fluctuations are detected, a high-shear mixing anomaly warning is automatically generated, prompting the operator to adjust mixing parameters or check the mixing process to avoid material agglomeration or uneven dispersion. If no abnormal fluctuations are detected, the secondary agglomeration certification is passed, indicating that the material exhibits uniform particle distribution and stable flowability during high-shear mixing, meeting the expected quality standards. Once certification is passed, the batch of material is considered qualified, and the target mixed material is obtained.

[0063] Step S600: The target mixed material is extruded from the extruder die to form a continuous strip material. After the strip material is cooled and solidified, the masterbatch is cut using a pelletizer to obtain the target halogen-free flame-retardant cable shell material.

[0064] In this embodiment, the extruder uses the high shear force and heating effect of a twin-screw extrusion to extrude the target mixture from the extruder die, forming a continuous strip of material. After the strip of material is extruded from the extruder die, it is conveyed to a cooling device, where a water-cooling or air-cooling system is used to cool the material. During this process, the temperature of the material gradually decreases, causing it to change from a molten state to a solid state. Through cooling, the strip of material solidifies.

[0065] After cooling and solidification, the strip material is conveyed to a pelletizer, which cuts the material into uniform masterbatch particles according to the set cutting length and particle size. These masterbatch particles are the halogen-free flame-retardant cable shell material.

[0066] In summary, the embodiments of this application have at least the following technical effects:

[0067] This application obtains the target manufacturing requirements for the target cable shell; based on the manufacturing requirements, it mines an internal database of shell material manufacturing to obtain a set of mining material manufacturing schemes. Each mining material manufacturing scheme includes additive addition time, halogen-free flame retardant and reinforcing material addition ratio, initial stirring time, twin-screw extruder shear force, and twin-screw extruder mixing intensity; based on the mining material manufacturing scheme set, the schemes are screened to determine the first material manufacturing scheme; the raw materials are initially mixed using a high-speed mixer according to the first material manufacturing scheme. When the stirring time meets the initial stirring time, the mixed particles are subjected to a first agglomeration certification. If the first agglomeration certification is passed, the preliminary mixed material is obtained; the preliminary mixed material is subjected to high-shear mixing using a twin-screw extruder according to the first material manufacturing scheme. During the mixing process, a melt flow rate meter is used to perform a second continuous agglomeration particle certification on the flow properties of the mixed material. If the second agglomeration certification is passed, the target mixed material is obtained; the target mixed material is extruded from the extruder die to form a continuous strip material. After the strip material is cooled and solidified, it is cut into masterbatch using a pelletizer to obtain the target halogen-free flame retardant cable shell material. This invention addresses the technical problem of insufficient precise control over the mixing process in existing technologies, which leads to low performance of the prepared halogen-free flame-retardant cable shell materials. By obtaining the preparation requirements of the target cable shell and combining database mining, mixing process optimization, and high-shear mixing equipment, the invention achieves real-time control of key parameters in the material preparation process, thereby achieving the technical effect of precise preparation of halogen-free flame-retardant cable shell materials.

[0068] It should be noted that the order of the embodiments described above is merely for descriptive purposes and does not represent the superiority or inferiority of the embodiments. Furthermore, the above description focuses on specific embodiments of this specification. The processes depicted in the accompanying drawings do not necessarily require a specific or sequential order to achieve the desired results. In some implementations, multitasking and parallel processing are possible or may be advantageous.

[0069] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application. This specification and drawings are merely illustrative examples of this application and are considered to cover any and all modifications, variations, combinations, or equivalents within the scope of this application. Obviously, those skilled in the art can make various alterations and modifications to this application without departing from the scope of this application. Thus, if these modifications and modifications of this application fall within the scope of this application and its equivalents, this application intends to include these modifications and modifications.

Claims

1. A method for preparing a reinforced halogen-free flame-retardant cable outer shell material, characterized in that, The method includes: Obtain the target fabrication requirements for the target cable shell; Based on the target preparation requirements, an internal database of shell material preparation is mined to obtain a set of material preparation schemes. Each material preparation scheme in the set includes additive addition time, halogen-free flame retardant and reinforcing material addition ratio, initial stirring time, twin-screw extruder shear force and twin-screw extruder mixing intensity. Based on the set of mining material preparation schemes, a scheme is selected through centralized screening to determine the first material preparation scheme; The raw materials are initially mixed using a high-speed mixer according to the first material preparation scheme. After the mixing time meets the initial mixing time, the mixed particles are subjected to an agglomeration certification. If the agglomeration certification is passed, the initial mixed material is obtained. The preliminary mixed material is subjected to high-shear mixing using a twin-screw extruder according to the first material preparation scheme. During the mixing process, a melt flow rate meter is used to perform secondary continuous agglomeration particle certification on the flow properties of the mixed material. If the secondary agglomeration certification is passed, the target mixed material is obtained. The target mixture is extruded from the extruder die to form a continuous strip material. After the strip material is cooled and solidified, the masterbatch is cut using a pelletizer to obtain the target halogen-free flame-retardant cable shell material. The step of selecting a first material preparation scheme based on the set of mining material preparation schemes includes: Based on the set of mining material preparation schemes, a screening space is constructed to obtain a centralized screening space, wherein the centralized screening space includes multiple screening particle points, and each screening particle point corresponds to a mining material preparation scheme. M screening particle points are randomly selected from the plurality of screening particle points. The M screening particle points are used as starting points and the iteration region in the centralized screening space is divided according to the preset iteration bandwidth to obtain M screening iteration regions. Here, M is an integer greater than or equal to 1. The preset iteration bandwidth refers to dividing the screening space into several sub-regions according to parameter differences. Each region contains a set of similar particle points. The screening density is calculated by traversing the M screening iteration regions to obtain M screening densities. The screening particle point corresponding to the maximum value among the M screening densities is taken as the screening head particle, and the remaining M-1 screening particle points are taken as the screening tail particle set. Using the screening head particle as the iteration direction, the screening tail particle set is iterated in the concentrated screening space according to the preset iteration bandwidth. It is determined whether there is a density in the screening density set of the iterative tail particles that is greater than the screening density of the screening head particle. If so, the iterative tail particle corresponding to the maximum value in the screening density set of the iterative tail particles is updated as the screening head particle, and the iterative screening continues until the preset iteration stop condition is met. The screening head particle obtained in the last iteration is taken as the target screening particle point, and the mining material preparation scheme corresponding to the target screening particle point is taken as the first material preparation scheme. The preset iteration stop condition is that the difference in screening density of two screening head particles obtained in two adjacent iterations is less than or equal to the preset screening density difference.

2. The method for preparing a reinforced halogen-free flame-retardant cable shell material as described in claim 1, characterized in that, include: Obtain the application flame retardancy rating of the target cable shell, and use the application flame retardancy rating as the first sub-manufacturing requirement; Obtain the required tensile strength, required impact strength, and required bending resistance of the target cable shell, and generate a second sub-manufacturing requirement; The first sub-preparation requirement and the second sub-preparation requirement are taken as the target preparation requirement.

3. The method for preparing a reinforced halogen-free flame-retardant cable outer shell material as described in claim 2, characterized in that, Based on the aforementioned preparation requirements, an internal database of shell material preparation was mined to obtain a set of material preparation schemes, including: Using the first sub-preparation requirement and the second sub-preparation requirement as indexes, data is retrieved from the internal database of shell material preparation to obtain a set of material preparation schemes. The set of retrieved material preparation schemes is subjected to difference verification. If the verification is successful, the set of retrieved material preparation schemes is used as the set of mined material preparation schemes. If authentication fails, cloud data mining instructions are obtained to acquire multiple cloud material preparation scheme sets to supplement the retrieved material preparation scheme set, and differential authentication is performed again until authentication is successful, thereby obtaining the mined material preparation scheme set.

4. The method for preparing a reinforced halogen-free flame-retardant cable shell material as described in claim 1, characterized in that, Using the head particle as the iteration direction, the set of tail particles is iterated in the concentrated screening space according to the preset iteration bandwidth. After multiple iterations until the preset iteration stopping condition is met, the target screening particle point is obtained. The mining material preparation scheme corresponding to the target screening particle point is taken as the first material preparation scheme, including: Using the screening head particle as the iteration direction, the screening tail particle set is iterated in the concentrated screening space according to the preset iteration bandwidth to obtain the iterated tail particle set. The set of iterative tail particles is traversed to perform screening density calculations, thereby obtaining the set of iterative tail particle screening densities. Determine whether there exists a density greater than that of the screening head particle in the set of iterative tail particle screening densities. If so, update the iterative tail particle corresponding to the maximum value in the set of iterative tail particle screening densities to the screening head particle, and continue iterative screening until the preset iteration stop condition is met. Then, take the screening head particle obtained in the last iteration as the target screening particle point.

5. The method for preparing a reinforced halogen-free flame-retardant cable shell material as described in claim 1, characterized in that, The raw materials are initially mixed using a high-speed mixer according to the first material preparation scheme. After the mixing time meets the initial mixing time requirement, the mixed particles undergo an agglomeration certification. If the agglomeration certification is successful, a preliminary mixed material is obtained, comprising: Random sampling was performed on the mixed particles to obtain multiple preliminary mixed particle samples; The particle morphology of the multiple preliminary mixed particle samples was analyzed using an optical microscope to determine the agglomeration analysis results of the multiple preliminary samples. The aggregation analysis results of the multiple preliminary samples are comprehensively analyzed, and an aggregation certification result is obtained based on the analysis results. If the aggregation certification result is a successful aggregation certification, the preliminary mixed material is obtained.

6. The method for preparing a reinforced halogen-free flame-retardant cable shell material as described in claim 1, characterized in that, The preliminary mixed material is subjected to high-shear mixing using a twin-screw extruder according to the first material preparation scheme. During the mixing process, a melt flow rate meter is used to perform secondary continuous agglomeration particle certification on the flow properties of the mixed material. If the secondary agglomeration certification is passed, the target mixed material is obtained, including: The melt flow rate meter is used to continuously monitor the flow properties of the mixed materials to obtain the melt flow rate sequence and the melt volume flow rate sequence, wherein the melt flow rate and the melt volume flow rate have a one-to-one mapping relationship. Based on the melt flow rate sequence and the melt volume flow rate sequence, the melt viscosity is calculated to obtain the melt viscosity sequence; Abnormal fluctuations are identified in the melt viscosity sequence. If abnormal fluctuations are found, a high-shear mixing abnormality warning command is obtained. If there are no abnormal fluctuations, the secondary agglomeration certification is passed, and the target mixed material is obtained.

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