Wire cable and production and processing technology thereof

Abstract

The invention provides a wire and cable and a production and processing technology thereof, and belongs to the technical field of wires and cables, the wire and cable specifically comprises a plurality of wires, an insulating layer and a protective layer, the two ends of the plurality of wires are aligned and gathered together, the insulating layer wraps the wires, the protective layer wraps the insulating layer, and the protective layer wraps the insulating layer. The insulating layer is made of supercritical foaming materials, and the protective layer is made of light high-strength polymers. Through the processing scheme provided by the invention, the laying efficiency of the wires and cables is improved.

Description

Technical Field

[0001] This application relates to the field of wire and cable, and particularly to a wire and cable and its production and processing technology. Background Art

[0002] Cables, also known as wire and cables, are the main carriers of power transmission and are widely used in electrical equipment, lighting circuits, household appliances, etc. The quality of cables directly affects the project quality and the life and property safety of consumers. With the development of technology, the technology of wire and cable has become more and more mature, and the cable laying across the country has basically achieved full residential area coverage.

[0003] Currently, during the long-distance power transmission of cables, due to the different environmental landforms in different places, it is necessary to carry out multi-layer protection on the conductor to prevent the conductor from being damaged due to harsh environments during power transmission, which affects power transmission. The outer layer of the cable conductor needs to have effects such as insulation, abrasion resistance, and corrosion resistance. In the prior art, the multi-layer wrapping superposition effect is usually used, but the superposition greatly increases the weight of the cable, so large-scale laying equipment needs to be brought in for construction during the cable laying process. If it is a mountainous area where large equipment cannot enter, a large amount of labor is required to transfer and lay the cable, which greatly consumes labor and reduces work efficiency. Summary of the Invention

[0004] In view of this, this application provides a wire and cable and its production and processing technology, which solves the problem of excessive weight of wire and cable in the prior art and improves the laying efficiency of the cable.

[0005] The wire and cable and its production and processing technology provided by this application adopt the following technical solutions:

[0006] A wire and cable includes a conductor, an insulating layer, and a protective layer. There are multiple conductors, and the two ends of the multiple conductors are aligned and gathered. The insulating layer is wrapped outside the conductor, and the protective layer is wrapped outside the insulating layer. The insulating layer is a supercritical foaming material, and the protective layer is a lightweight and high-strength polymer.

[0007] Optionally, the inner layer of the insulating layer is spiral corrugated, the wave crest height is 0.5 - 1.0 mm, and the pitch is 2 - 4 mm.

[0008] Optionally, the supercritical foaming material used for the insulating layer is TPU.

[0009] Optionally, the protective layer is a regular hexagonal honeycomb unit, the aperture of the regular hexagon is 1 - 2 mm, and the wall thickness is 0.2 - 0.3 mm.

[0010] Optionally, the lightweight and high-strength polymer used for the protective layer is a glass fiber reinforced PP material.

[0011] Optionally, the wire and cable comprises raw materials in the following parts by weight:

[0012] 100 parts of TPU, 4 parts of nano-silica, 6.5 parts of carbon fiber, 0.7 part of silane coupling agent, 0.3 part of antioxidant, 0.5 part of lubricant;

[0013] 100 parts of glass fiber reinforced PP material, 18 parts of hollow glass microspheres, 4 parts of compatibilizer, 2 parts of anti-UV agent, 13 parts of flame retardant, 0.2 part of nucleating agent.

[0014] By adopting the above technical solution, the silane coupling agent forms a chemical bridge between the carbon fiber and the nano-silica to construct a three-dimensional reinforcement network; the spiral corrugated die head forms wave crests of 0.5 - 1.0 mm through the melt directional flow and forms a mechanical interlocking structure after cooling and shaping. At the same time, the TPU matrix generates a closed-cell structure with a porosity of 30% - 50% through supercritical CO2 foaming, effectively reducing the mass of the insulating layer; the glass fiber reinforced PP material and the hollow glass microspheres form an interfacial bond through the compatibilizing effect of maleic anhydride grafted PP and are injection molded into a regular hexagonal honeycomb shape, reducing the mass of the protective layer while enhancing the wear resistance and corrosion resistance of the protective layer.

[0015] A production and processing process for a wire and cable, optionally, comprising the following process steps:

[0016] S1: High-speed blend nano-silica, carbon fiber and silane coupling agent, connect the carbon fiber on the surface of the silica to obtain modified material A, and add the modified material A, dried TPU particles, antioxidant and lubricant to a twin-screw extruder to obtain an insulating layer;

[0017] S2: Add glass fiber reinforced PP material, hollow glass microspheres, compatibilizer, nucleating agent, anti-UV agent and flame retardant to a mixer, mix them and then take out the mixture and add it to a twin-screw extruder to obtain a honeycomb special masterbatch to obtain a protective layer;

[0018] S3: Co-extrude the insulating layer obtained in S1 and the honeycomb special masterbatch obtained in S2 using a double-layer co-extrusion die head, inject carbon dioxide gas synchronously to obtain a corrugated-honeycomb composite sleeve, and insert the wire into the corrugated layer of the corrugated-honeycomb composite sleeve and extrude plastically to obtain a wire and cable.

[0019] Optionally, the silane coupling agent in S1 is KH-550, the antioxidant is antioxidant 1010, and the lubricant is zinc stearate.

[0020] Optionally, the compatibilizer in S2 is maleic anhydride grafted PP, the anti-UV agent is titanium dioxide, the flame retardant is aluminum hydroxide, and the nucleating agent is a sorbitol derivative.

[0021] By adopting the above technical solution, the inner layer of TPU and the outer layer of PP are combined under the interlayer pressure, and a chemical bonding interface is formed through the mutual diffusion of molecular chain segments. The geometric matching design of the corrugated-honeycomb structure makes the stress distributions of the two layers complementary: the helical corrugated layer disperses the axial tensile force through a 45° inclination angle, and the honeycomb layer absorbs the radial impact through the hexagonal cells.

[0022] In summary, the present application includes the following beneficial technical effects:

[0023] 1. Through the forming process of the helical corrugated structure of nano-silica / carbon fiber modified TPU in step S1, the uniform dispersion of the fillers is realized by using a twin-screw extruder. The silane coupling agent forms a chemical bridge between the carbon fiber and the nano-silica to construct a three-dimensional reinforcement network; the 45° helical teeth of the helical corrugated die head form wave crests of 0.5 - 1.0 mm through the directional flow of the melt, and a mechanical interlocking structure is formed after cooling and shaping. At the same time, the TPU matrix generates a closed-cell structure with a porosity of 30% - 50% through supercritical CO2 foaming.

[0024] 2. In step S2, the composite system of glass fiber reinforced PP and hollow glass microspheres realizes the interfacial bonding between the glass fiber and the microspheres during injection molding through the compatibilizing effect of maleic anhydride grafted PP. The regular hexagonal honeycomb mold controls the melt filling through a high-precision hot runner to form honeycomb cells with equal wall thickness.

[0025] 3. Step S3 adopts the double-layer co-extrusion die head synchronous forming technology, the inner layer of TPU and the outer layer of PP are combined under the interlayer pressure, and a chemical bonding interface is formed through the mutual diffusion of molecular chain segments. The geometric matching design of the corrugated-honeycomb structure makes the stress distributions of the two layers complementary: the helical corrugated layer disperses the axial tensile force through a 45° inclination angle, and the honeycomb layer absorbs the radial impact through the hexagonal cells. Brief Description of the Drawings

[0026] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required to be used in the embodiments will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present application. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0027] Figure 1 It is an end face plan view of a wire and cable disclosed in an embodiment of the present application;

[0028] Figure 2 It is a cross-sectional view of a wire and cable disclosed in an embodiment of the present application.

[0029] Description of the reference numerals: 1. Conductive wire; 2. Insulating layer; 21. Helical corrugation; 3. Protective layer; 31. Regular hexagonal honeycomb. Detailed Description of the Embodiments

[0030] The embodiments of the present application will be described in detail below with reference to the accompanying drawings.

[0031] The following specific examples illustrate the implementation manners of the present application. Those skilled in the art can easily understand other advantages and effects of the present application from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. The present application can also be implemented or applied through other different specific implementation manners. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present application. It should be noted that, without conflict, the following embodiments and the features in the embodiments can be combined with each other. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in the present application without creative efforts belong to the scope of protection of the present application.

[0032] It should be noted that the following description relates to various aspects of embodiments within the scope of the appended claims. It should be apparent that the aspects described herein can be embodied in a wide variety of forms, and any specific structure and / or function described herein is illustrative only. Based on the present application, those skilled in the art should understand that one aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number of aspects described herein can be used to implement the device and / or practice the method. In addition, this device can be implemented and this method can be practiced using other structures and / or functionality in addition to one or more of the aspects described herein.

[0033] It should also be noted that the drawings provided in the following embodiments only schematically illustrate the basic concept of the present application. The drawings only show the components related to the present application, rather than being drawn according to the number, shape, and size of the components in actual implementation. The type, quantity, and ratio of each component in actual implementation can be arbitrarily changed, and the component layout type may also be more complex.

[0034] In addition, in the following description, specific details are provided to facilitate a thorough understanding of the examples. However, those skilled in the art will understand that the described aspects can be practiced without these specific details.

[0035] An embodiment of the present application provides a wire and cable. Referring to Figure 1 and Figure 2 , it includes a conductor 1, an insulating layer 2, and a protective layer 3. There are multiple conductors 1, and the two ends of the multiple conductors 1 are aligned and gathered. The insulating layer 2 is wrapped outside the conductor 1, and the protective layer 3 is wrapped outside the insulating layer 2. The insulating layer 2 is a supercritical foaming material, and the protective layer 3 is a lightweight and high-strength polymer.

[0036] The insulating layer 2 is made of supercritical carbon dioxide foamed TPU, with a spiral corrugated inner layer 21, a wave crest height of 0.5 - 1.0 mm, and a pitch of 2 - 4 mm.

[0037] The protective layer 3 is made of glass fiber reinforced PP material, with regular hexagonal honeycomb 31 units, a regular hexagonal aperture of 1 - 2 mm, and a wall thickness of 0.2 - 0.3 mm.

[0038] A production process for wire and cable:

[0039] I. Raw material preparation

[0040] 1. Materials for the insulating layer 2 (by weight):

[0041] TPU (thermoplastic polyurethane, BASF Elastollan C85A) 100 parts;

[0042] Nano-silica (30 - 50 nm, lipophilic modification) 4 parts;

[0043] Short carbon fiber filaments (length 3 mm, diameter 7 μm) 6.5 parts;

[0044] Silane coupling agent (KH-550, Dow Corning) 0.7 parts;

[0045] Antioxidant 1010 (BASF) 0.3 parts;

[0046] Zinc stearate (lubricant) 0.5 parts;

[0047] 2. Materials for the protective layer 3 (by weight):

[0048] Glass fiber reinforced PP (30% glass fiber content, Kingfa Science & Technology) 100 parts;

[0049] Hollow glass microspheres (particle size 20 - 50 μm, density 0.6 g / cm 3 ) 18 parts;

[0050] Maleic anhydride grafted PP 4 parts;

[0051] Titanium dioxide (UV resistant agent, DuPont R-902) 2 parts;

[0052] Aluminum hydroxide (flame retardant, particle size 2 - 5 μm) 13 parts;

[0053] Sorbitol derivative (nucleating agent, Millad NX8000) 0.2 parts

[0054] II. Preparation process steps

[0055] 1. Step S1: Preparation of the insulating layer 2

[0056] Pretreatment and modification:

[0057] Dry the TPU particles in an oven at 80 °C for 4 hours to make the moisture content < 0.05%;

[0058] Add nano-silica, carbon fiber and silane coupling agent to a high-speed mixer, rotate at 1200 rpm and mix for 5 minutes to form a surface-modified three-dimensional network structure to obtain modified material A.

[0059] Melt co-extrusion and foaming:

[0060] Add modified material A, dried TPU, antioxidant 1010 and zinc stearate to a twin-screw extruder. Temperature zones: zone 1 at 180 °C / zone 2 at 195 °C / zone 3 at 200 °C / zone 4 at 195 °C / die at 190 °C;

[0061] Inject supercritical CO2 at the die at a temperature of 35 °C and a pressure of 10 MPa, and form a closed-cell microporous structure by rapid pressure reduction;

[0062] Use a 45° helical rotating die to extrude a spiral corrugated structure with a wave peak height of 0.8 mm and a pitch of 2 mm, and cool and solidify it through a water-cooled sizing sleeve with a water temperature of 15 °C.

[0063] 2. Step S2: Preparation of protective layer 3

[0064] Masterbatch preparation:

[0065] Add glass fiber-reinforced PP, hollow glass microspheres, maleic anhydride-grafted PP, titanium dioxide, aluminum hydroxide and sorbitol derivatives to a high-speed mixer, rotate at 800 rpm and mix for 10 minutes;

[0066] Pelletize through a twin-screw extruder at a temperature of 210 °C to obtain a special honeycomb masterbatch.

[0067] Injection molding:

[0068] Use a hot runner mold, with a regular hexagonal honeycomb of 31 cells, a pore diameter of 1.5 mm and a wall thickness of 0.25 mm;

[0069] Injection molding parameters: barrel temperature 210 °C / 220 °C / 225 °C / 220 °C, injection pressure 80 MPa, holding pressure 40 MPa, cooling time 15 seconds;

[0070] Spray a fluorosilane nano-coating on the honeycomb surface with a thickness of 5 μm and cure it at 150 °C for 30 minutes to form a hydrophobic surface.

[0071] 3. Step S3: Composite co-extrusion and cable forming

[0072] Double-layer co-extrusion:

[0073] Synchronously feed the insulating layer 2 and the protective layer 3 into a double-layer co-extrusion die;

[0074] The interfacial bonding pressure is 1.8 MPa, the traction speed is 1.5 m / min, and the total thickness is monitored by an on-line thickness gauge.

[0075] Conductor encapsulation:

[0076] Insert multiple copper wires 1 with a diameter of 1.5 mm into the corrugated layer, and plastically form them by a roll press with a pressure of 5 MPa to form a tightly wrapped structure.

[0077] The working principle involved in this application:

[0078] Insulating layer 2: The inner spiral corrugations 21 of the insulating layer 2 are evenly and regularly distributed along the inner surface of the insulating layer. The microporous closed-cell structure is evenly distributed in the base material of the insulating layer. The microporous closed-cell structure not only makes the material lighter but also effectively enhances the mechanical properties and insulating properties of the material, which helps to protect the wire 1 located therein.

[0079] Protective layer 3: Hollow glass microspheres are evenly distributed in the protective layer 3. The base material of the protective layer 3 is glass fiber-modified PP. After the addition of the hollow glass microspheres, the wear resistance and corrosion resistance of the protective layer 3 are further improved. The interior of the protective layer 3 is filled with a uniformly distributed regular hexagonal honeycomb 31 structure, which greatly improves the lightweight of the protective layer 3, making the protective layer 3 lightweight while having wear resistance and corrosion resistance. The added anti-UV agent and flame retardant can correspondingly improve the anti-ultraviolet and flame retardant capabilities of the wire and cable during use.

[0080] The geometric matching design of the above corrugation-honeycomb structure makes the stress distributions of the two layers complementary: the spiral corrugated layer disperses the axial tension through a 45° inclination angle, and the honeycomb layer absorbs the radial impact through the hexagonal units. The connection interface between the microporous structure and the regular hexagonal honeycomb enables some micropores and the regular hexagonal honeycomb structure to communicate, which not only improves the impact resistance of the wire and cable but also enhances the insulation effect simultaneously.

[0081] III. Performance testing

[0082] Lightweight: The density of the insulating layer 2 is 0.78 g / cm 3 (30% lower than traditional TPU), and the linear density of the protective layer 3 is 110 g / m (60% lighter than the solid sheath);

[0083] Insulating performance: The breakdown field strength is 38 kV / mm (50% improvement), and the dielectric constant is 1.9 @ 1 MHz (20% reduction);

[0084] Mechanical strength: The compressive strength is 36 MPa (140% improvement), and the dynamic bending life is 120,000 times (IEC 60227-1 standard);

[0085] Environmental adaptability: Flame retardant grade UL94 V-0 (1.6 mm thickness), salt spray resistance test > 2000 h (no corrosion).

[0086] The above are only specific embodiments of the present application, but the protection scope of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present application should be covered by the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.

Claims

1. A wire and cable, characterized in that, It includes a wire (1), an insulating layer (2), and a protective layer (3). There are multiple wires (1), and the two ends of the multiple wires (1) are aligned and gathered. The insulating layer (2) is wrapped outside the wire (1), and the protective layer (3) is wrapped outside the insulating layer (2). The insulating layer (2) is a supercritical foaming material, and the protective layer (3) is a lightweight and high-strength polymer.

2. The wire and cable according to claim 1, characterized in that, The inner layer of the insulating layer (2) is in a spiral corrugated shape (21), with a wave crest height of 0.5 - 1.0 mm and a pitch of 2 - 4 mm.

3. A wire and cable according to claim 2, characterized in that, The supercritical foaming material used for the insulating layer (2) is TPU.

4. A wire and cable according to claim 3, characterized in that, The protective layer (3) is a regular hexagonal honeycomb (31) unit, with a regular hexagonal aperture of 1 - 2 mm and a wall thickness of 0.2 - 0.3 mm.

5. A wire and cable according to claim 4, characterized in that, The lightweight and high-strength polymer used for the protective layer (3) is a glass fiber reinforced PP material.

6. A wire and cable according to claim 5, characterized in that, The wire and cable includes the following raw materials in parts by weight: 100 parts of TPU, 4 parts of nano-silica, 6.5 parts of carbon fiber, 0.7 part of silane coupling agent, 0.3 part of antioxidant, 0.5 part of lubricant; 100 parts of glass fiber reinforced PP material, 18 parts of hollow glass microspheres, 4 parts of compatibilizer, 2 parts of anti-UV agent, 13 parts of flame retardant, 0.2 part of nucleating agent.

7. The production and processing technology of the wire and cable according to any one of claims 1-6, characterized in that, It includes the following technological steps: S1: High-speed blend nano-silica, carbon fiber, and silane coupling agent, connect the carbon fiber on the surface of the silica to obtain modified material A. Add modified material A, dried TPU particles, antioxidant, and lubricant to a twin-screw extruder to obtain the insulating layer (2); S2: Add glass fiber reinforced PP material, hollow glass microspheres, compatibilizer, nucleating agent, anti-UV agent, and flame retardant to a mixer, mix them and then take out the mixture and add it to a twin-screw extruder to obtain a honeycomb special masterbatch to get the protective layer (3); S3: Co-extrude the insulating layer (2) obtained in S1 and the honeycomb special masterbatch obtained in S2 using a double-layer co-extrusion die head, simultaneously inject carbon dioxide gas to obtain a corrugated-honeycomb composite sleeve, and insert the wire (1) into the corrugated layer of the corrugated-honeycomb composite sleeve and extrude and plastify to obtain the wire and cable.

8. A wire and cable production and processing process according to claim 7, characterized in that, The silane coupling agent in S1 is KH-550, the antioxidant is antioxidant 1010, and the lubricant is zinc stearate.

9. A wire and cable production and processing process according to claim 7, characterized in that, The compatibilizer in S2 is maleic anhydride grafted PP, the anti-UV agent is titanium dioxide, the flame retardant is aluminum hydroxide, and the nucleating agent is a sorbitol derivative.

Images