High-flexibility anti-static cable and manufacturing process thereof

Abstract

The invention provides a high-flexibility anti-static cable and a manufacturing process thereof, and relates to the field of cables. Comprising a conductor layer, an insulating layer, a shielding layer, a wrapping layer and an outer protective layer which are sequentially arranged from inside to outside, raw materials of the outer protective layer comprise polyurethane and carbon powder, and the mass ratio of the polyurethane to the carbon powder is (80-99): (1-20). The outer protective layer is prepared by mixing the polyurethane and the carbon powder according to the specified proportion, so that the anti-static capability of the cable can be greatly improved on the basis of not increasing the cost and not changing the flexibility of the cable material.

Description

Technical Field

[0001] The present invention relates to the field of cables, and in particular, to a highly flexible anti-static cable and its manufacturing process. Background Art

[0002] Cables have many uses, mainly for control installation, connecting devices, transmitting electricity, etc. They are a common and indispensable item in daily life. In some usage scenarios, the safety requirements for preventing fire are particularly high. For example, when used in oil tanks, oil wells, and large oil storage container environments, the cable is in direct long-term contact with or immersed in oil, and is used to connect with measuring instruments and sensors to transmit control signals and measurement signals. The cable is in close contact with fuel during use and is used in a mobile manner. If the cable sheath does not have anti-static function, static electricity will inevitably be generated due to the friction between the cable sheath and the fuel. Since fuel has high insulation, the more static electricity accumulates, and with the increase in voltage, in case of discharge, it will generate electric sparks, causing fuel fire and explosion. Therefore, the flexibility and anti-static ability of the sheath are very important. Another example is the semiconductor industry, where static electricity will undoubtedly have a fatal impact on chips.

[0003] Since the consumption of cables is very large, economy is also an important issue to be considered in the cable manufacturing process. Currently, the mainstream cable sheath materials on the market are mainly three types. The first type is to use PVC as the cable sheath material. The cables in this direction do not have anti-static ability, but they are cost-effective. The cables are rigid and are applied to scenarios where no mobile use is required and cannot prevent static electricity. The second type is to use polyolefin materials as the cable sheath material. The cables in this direction usually have good flexibility, but are prone to aging and damage. And after being irradiated by electron beams, the atoms on the surface material will be ionized and excited, generating free charges on the surface of the cable, and also cannot prevent static electricity. The third type is to use LSZH (low smoke and halogen-free material) as the cable sheath material, which has the characteristic of fire prevention, but the price of LSZH materials is relatively high.

[0004] In summary, there is a need for an economical, anti-static, and highly flexible cable to solve the above problems. Summary of the Invention

[0005] The purpose of the present invention is to provide a highly flexible anti-static cable and its manufacturing process, which can greatly increase the anti-static ability of the cable without increasing costs and without changing the flexibility of the cable material.

[0006] To solve the above technical problems, the technical solution adopted by the present invention is as follows:

[0007] A highly flexible anti-static cable and its manufacturing process, including a conductor layer, an insulating layer, a shielding layer, a wrapping layer, and an outer sheath arranged in sequence from inside to outside. The raw materials of the outer sheath include polyurethane and carbon powder. Among them, the mass ratio of the polyurethane to the carbon powder is 80 - 99:1 - 20.

[0008] Further, in the present invention, the conductor layer is made of tinned copper-clad aluminum alloy wire.

[0009] Further, in the present invention, the insulating layer is made of platinum-cured silicone rubber.

[0010] Further, in the present invention, the shielding layer is made by double braiding tinned copper-clad aluminum alloy wire and nylon wire.

[0011] Further, in the present invention, the wrapping layer is formed by winding an aluminum-plastic composite tape.

[0012] Further, in the present invention, a roundness compensation filling material is filled between the conductor layer and the insulating layer.

[0013] Further, in the present invention, the roundness compensation filling material is one of epoxy resin, polyester, nylon, or hemp rope.

[0014] A manufacturing process of a highly flexible anti-static cable includes the following steps:

[0015] Prepare tinned copper-clad aluminum alloy wire and select part of it as the conductor layer;

[0016] Extrude platinum-cured silicone rubber on the outside of the conductor layer to form an insulating layer;

[0017] Use part of the tinned copper-clad aluminum alloy wire and nylon wire for double braiding to form a shielding layer and cover the shielding layer on the outside of the insulating layer;

[0018] Wind and cover an aluminum-plastic composite tape on the outside of the shielding layer to form a wrapping layer;

[0019] Prepare the outer sheath material and cover the outer sheath material on the outside of the wrapping layer to form an outer sheath; among them, the outer sheath material includes polyurethane and carbon powder, and the mass ratio of the polyurethane to the carbon powder is 80 - 99:1 - 20.

[0020] Further, in the present invention, the step of preparing the outer sheath material and covering the outer sheath material on the outside of the wrapping layer to form an outer sheath includes:

[0021] Mix and shake polyurethane and carbon powder in a specified proportion to obtain a mixture;

[0022] Heat the mixture to a specified temperature to form a molten mixture;

[0023] The molten mixture is extruded outside the wrapping layer through an extruder to form an outer sheath.

[0024] Further, in the present invention, the specified temperature is 200°C - 250°C.

[0025] The present invention has at least the following advantages or beneficial effects:

[0026] The present invention forms an anti-static cable by sequentially arranging a conductor layer, an insulating layer, a shielding layer, a wrapping layer, and an outer sheath from the inside to the outside. The raw materials of the outer sheath include polyurethane and carbon powder. Among them, the mass ratio of polyurethane to the carbon powder is 80 - 99:1 - 20. As the directly contacting part, polyurethane is used as the main component of the cable outer sheath, meeting the requirements of flexibility, toughness, self-lubricating characteristics, not easily ionizing to generate free charges, good weather resistance, not easily being eroded by oil stains, etc. required for cables in mobile scenarios, which can basically solve the anti-static requirements of the cable. At the same time, carbon powder is added as a modified additive material to the polyurethane raw material, so that while the cable sheath retains the advantage of not easily generating static electricity, the density is not increased, and at the same time, it has a certain conductivity. Any position of the cable can be grounded when directly or indirectly contacting the ground, and therefore, without special treatment basically, it has reliable anti-static performance. By using polyurethane and carbon powder to be mixed and prepared in a specified ratio to form the outer sheath, the present application can greatly increase the anti-static ability of the cable without increasing the cost and without changing the flexibility of the cable material. Description of the Drawings

[0027] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required to be used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention, and therefore should not be regarded as limiting the scope. For those of ordinary skill in the art, other related drawings can be obtained based on these drawings without creative efforts.

[0028] Figure 1 It is a flowchart of the steps of the manufacturing process of the high-flex anti-static cable provided by the embodiment of the present application. Detailed Embodiments

[0029] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. Generally, the components of the embodiments of the present invention described and illustrated in the drawings here can be arranged and designed in various different configurations.

[0030] Accordingly, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the scope of protection of the present invention.

[0031] Embodiment

[0032] This embodiment provides a highly flexible anti-static cable, which includes a conductor layer, an insulating layer, a shielding layer, a wrapping layer, and an outer sheath arranged in sequence from inside to outside. The raw materials of the outer sheath include polyurethane and carbon powder, wherein the mass ratio of the polyurethane to the carbon powder is 80 - 99:1 - 20.

[0033] Next, a highly flexible anti-static cable of this exemplary embodiment will be further described.

[0034] In some embodiments of the present application, the above-mentioned conductor layer is made of tinned copper-clad aluminum alloy wire.

[0035] By using tinned copper-clad aluminum alloy wire, compared with conventional copper wires in the prior art, tinned copper-clad aluminum alloy wire has huge advantages such as light weight, low cost, not easy to break during production and processing, and good tensile performance, making the cable have a small resistivity, high strength, good bending performance, not easy to break, light weight, easy to weld, convenient for transportation and construction, reducing the labor intensity of workers. At the same time, in the metal futures market, the price of aluminum alloy is much lower than that of copper, enabling the present application to occupy an advantageous position in the market competition.

[0036] As a preferred implementation manner, the above-mentioned insulating layer is made of platinum-cured silicone rubber material. Platinum-cured silicone rubber has higher flexibility and corrosion resistance compared with ordinary silicone rubber. Using it as the insulating layer makes the cable have high flexibility and high corrosion resistance, and can be applied to mobile use scenarios and scenarios such as long-term contact or immersion in oil, with good stability and the ability to extend the service life.

[0037] As a preferred implementation manner, the above-mentioned shielding layer is woven bidirectionally by tinned copper-clad aluminum alloy wire and nylon wire. After combining the high strength, high elasticity, heat resistance, wear resistance, self-lubrication and other characteristics of nylon wire with several characteristics of tinned copper-clad aluminum alloy wire, the formed shielding layer has good characteristics and can improve the insulation, strength and stability of the cable.

[0038] As a preferred implementation manner, the above-mentioned wrapping layer is wound by an aluminum-plastic composite tape. The aluminum-plastic composite tape has high temperature-resistant insulation ability and is safe to use.

[0039] In some embodiments of the present application, the raw materials of the outer protective layer include polyurethane and carbon powder, wherein the mass ratio of the polyurethane to the carbon powder is 80-99:1-20.

[0040] It should be noted that, as the main contact layer, the outer protective layer needs to generate friction with substances such as fuel. To improve the use safety, it is necessary to ensure that the generated static electricity is less and the material itself is not easily ionized and excited to generate free charges. Therefore, the outer protective layer of the present application is prepared by mixing polyurethane and carbon powder in a certain proportion. Polyurethane accounts for a relatively large proportion and is the main component of the outer protective layer. The characteristics of polyurethane are suitable for the characteristics required by the cable in this scenario: soft, tough, self-lubricating, not easily ionized to generate free charges, good weather resistance, not easily eroded by oil and grease, etc. It can basically meet the requirements of anti-static of the cable. At the same time, carbon powder is added to the polyurethane raw material as a modified additive material, so that the outer protective layer of the cable retains the advantage of not easily generating static electricity, does not increase the density, and at the same time has a certain conductivity. Any position of the cable can be grounded directly or indirectly in contact with the ground. Therefore, without special treatment basically, it has reliable anti-static performance.

[0041] As a preferred embodiment, a circularity filling material is filled between the conductor layer and the insulating layer to ensure the roundness of the cable. The circularity filling material is one of epoxy resin, polyester, nylon or hemp rope, with good insulation, softness, high toughness and high cost performance. Specifically, the circularity filling material is filled axially in strips, and the circularity filling material is bonded with a rubber self-adhesive tape.

[0042] Refer to Figure 1 This application embodiment also provides a manufacturing process of a highly flexible anti-static cable, including the following steps:

[0043] S110. Prepare a tinned copper-clad aluminum alloy wire and select a part as the conductor layer;

[0044] S120. Extrude platinum vulcanized silica gel on the outside of the conductor layer to form an insulating layer;

[0045] S130. Perform two-way braiding on a part of the tinned copper-clad aluminum alloy wire and nylon wire to form a shielding layer and cover the shielding layer on the outside of the insulating layer;

[0046] S140. Wind and cover an aluminum-plastic composite tape on the outside of the shielding layer to form a wrapping layer;

[0047] S150. Prepare the outer protective layer material and cover the outer protective layer material on the outside of the wrapping layer to form an outer protective layer; wherein, the outer protective layer material includes polyurethane and carbon powder, and the mass ratio of the polyurethane to the carbon powder is 80-99:1-20.

[0048] As a preferred embodiment, in the above step S150, the steps of preparing the outer sheath material and coating the outer sheath material on the outside of the wrapping layer to form the outer sheath include:

[0049] Pour polyurethane and carbon powder into a mixer in a specified ratio, mix and shake well to obtain a mixture;

[0050] Pour the mixture into an extruder and heat it to a specified temperature to form a molten mixture;

[0051] Extrude the molten mixture onto the outside of the wrapping layer through the extruder to form the outer sheath.

[0052] As a preferred embodiment, the above specified temperature is 200°C - 250°C; the specified ratio of polyurethane to carbon powder is 80 - 99:1 - 20. The higher the carbon powder content, the better the anti-static effect. However, correspondingly, the toughness of the outer sheath will be reduced, showing a normal distribution relationship. Therefore, setting it within this ratio range is the result of comprehensive trade-off, so that the outer sheath has a high anti-static effect while ensuring toughness.

[0053] In a specific embodiment, polyurethane and carbon powder are mixed in a ratio of 47:3 in a mixer, and the mixed polyurethane and carbon powder are poured into an extruder and heated. The heating temperature is 225°C. After heating to the molten state, it is extruded onto the outside of the wrapping layer through the extruder and cooled to obtain a cable. Confirm the anti-static property and conductivity of the outer sheath. Use a multimeter to measure the resistance value of the outer sheath at a distance of 200 mm for confirmation. If the resistance value is between 500 Ω and 2000 Ω, it indicates good anti-static property and conductivity. It should be noted that the larger the distance, the more accurate the resistance measurement value, but the operation difficulty will increase correspondingly; the smaller the distance, the lower the operation difficulty, but the accuracy of the resistance measurement value will also decrease. Measuring at a distance of 200 mm is simple to operate and can obtain an accurate resistance value.

[0054] The above are only the preferred embodiments of the present invention and are not used to limit the present invention. For those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A highly flexible anti-static cable, characterized in that, It includes a conductor layer, an insulating layer, a shielding layer, a wrapping layer and an outer sheath which are arranged in sequence from inside to outside. The raw materials of the outer sheath include polyurethane and carbon powder. Among them, the mass ratio of the polyurethane to the carbon powder is 80 - 99:1 - 20.

2. The highly flexible anti-static cable according to claim 1, wherein The conductor layer is made of tinned copper-clad aluminum alloy wire.

3. The high-flex anti-static wire and cable according to claim 1, characterized in that, The insulating layer is made of platinum-vulcanized silicone rubber.

4. The high-flex anti-static wire and cable according to claim 1, characterized in that The shielding layer is made by double braiding tinned copper-clad aluminum alloy wire and nylon wire.

5. The high-flex anti-static cable according to claim 4, wherein The wrapping layer is formed by winding an aluminum-plastic composite tape.

6. The high-flex anti-static wire and cable according to claim 1, characterized in that A circular filling material is filled between the conductor layer and the insulating layer.

7. The highly flexible anti-static cable according to claim 6, characterized in that, The circular filling material is one of epoxy resin, polyester, nylon or hemp rope.

8. The manufacturing process of a highly flexible anti-static cable, characterized in that, It includes the following steps: Prepare tinned copper-clad aluminum alloy wire and select part of it as the conductor layer; Extrude platinum-vulcanized silica gel on the outside of the conductor layer to form an insulating layer; Use part of the tinned copper-clad aluminum alloy wire and nylon wire for double braiding to form a shielding layer and wrap the shielding layer on the outside of the insulating layer; Wind and wrap an aluminum-plastic composite tape on the outside of the shielding layer to form a wrapping layer; Prepare the outer sheath material and wrap the outer sheath material on the outside of the wrapping layer to form an outer sheath; among them, the outer sheath material includes polyurethane and carbon powder, and the mass ratio of the polyurethane to the carbon powder is 80 - 99:1 - 20.

9. The manufacturing process according to claim 8, characterized in that, The step of preparing the outer sheath material and wrapping the outer sheath material on the outside of the wrapping layer to form an outer sheath includes: Mix and shake polyurethane and carbon powder in a specified ratio to obtain a mixture; Heat the mixture to a specified temperature to form a molten mixture; Extrude the molten mixture onto the outside of the wrapping layer through an extruder to form an outer sheath.

10. The manufacturing process according to claim 9, characterized in that, The specified temperature is 200°C - 250°C.

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