Carbon nanotube conductor lightweight flexible wire cable

Abstract

The invention discloses a carbon nano tube conductor lightweight flexible wire cable, the wire comprises a conductor and an insulating layer, the conductor is formed by twisting a plurality of copper / carbon nano tube composite monofilaments, the copper / carbon nano tube composite monofilaments are formed by wrapping copper flat filaments on carbon nano fibers, and the insulating layer is formed by wrapping the copper flat filaments on the carbon nano fibers. And the carbon nanofibers are formed by doubling a plurality of carbon nanotube twisted fibers. The wires are twisted into a cable, a plurality of copper / carbon nanotube composite monofilaments are wound on a cable core side by side to form a shielding layer, and an insulating layer is arranged on the outer layer of the shielding layer to form the cable. The wire cable effectively meets the aviation environment use requirements, and is high in mechanical property, excellent in tensile property, good in flexibility and long in bending life.

Description

Technical Field

[0001] The present invention belongs to the technical field of wire and cable manufacturing, and in particular relates to a lightweight and flexible wire and cable with a carbon nanotube conductor. Background Art

[0002] At present, copper conductor wires and cables are widely used in the domestic aviation field to transmit electrical energy and low-frequency signals. Due to the high density of copper and the heavy weight of cables, as more and more wires and cables are used in the aviation field, the requirements for lightweight and flexible cables are getting higher and higher. Copper conductor cables can no longer meet the usage requirements.

[0003] Carbon nanotubes have weak radial mechanical properties and are easily damaged by lateral compression and shear forces, making them impossible to connect to connectors using conventional cable crimping and welding methods.

[0004] Prior art techniques utilize carbon nanotubes and copper sheaths to form composite wires. CN115116673A discloses a method for preparing copper / carbon nanotube composite wires. First, carbon nanotube fibers are prepared through suspension catalysis or wet spinning. Multiple strands of these fibers are then twisted together to form a thicker carbon nanotube wire. After surface functionalization, the wire is then loaded into an oxygen-free copper tube with an inner diameter matching the diameter of the wire to form a copper / carbon nanotube composite precursor. This precursor is then subjected to high-temperature heat treatment to bond the carbon nanotube wire to the copper layer. Finally, the finished copper / carbon nanotube composite wire is produced through rolling, drawing, and other processing techniques. However, this conductor composite technology is either too difficult to manufacture or lacks sufficient strength. Summary of the Invention

[0005] In order to solve the above technical problems, the product of the present invention adopts an optimized composite of carbon nanotubes and copper to provide a new carbon nanotube conductor lightweight and flexible wire and cable.

[0006] The technical solution of the present invention is as follows: a lightweight and flexible electric wire with a carbon nanotube conductor, the electric wire includes a conductor and an insulating layer, the conductor is formed by twisting a plurality of copper / carbon nanotube composite monofilaments, the copper / carbon nanotube composite monofilaments are copper flat wires wrapped around carbon nanofibers, and the carbon nanofibers are formed by twisting a plurality of carbon nanotube fibers together.

[0007] Furthermore, the copper flat wire is silver-plated or nickel-plated.

[0008] Furthermore, the thickness of the copper flat wire is 0.020±0.008mm, Furthermore, the wrapping gap is 0.5% to 1.0%.

[0009] Furthermore, the insulating layer is composed of two layers, the inner layer is a PTFE / PI composite layer, and the outer layer is a PTFE layer.

[0010] Furthermore, the overlapping rates of the inner layer and the outer layer are both 51% to 54%.

[0011] Furthermore, the thickness of the PTFE / PI composite layer is 0.021 to 0.027 mm, and the thickness of the PTFE layer is 0.03 to 0.05 mm.

[0012] The present invention also provides a lightweight and flexible cable with a carbon nanotube conductor. The aforementioned electric wires are twisted into a cable, and a plurality of copper / carbon nanotube composite monofilaments are wound side by side on the cable core to form a shielding layer. The outer layer of the shielding layer is an insulating layer, the inner layer of the insulating layer is a PTFE / PI composite layer, and the outer layer is a PTFE layer.

[0013] Furthermore, the thickness of the PTFE / PI composite layer is 0.016-0.024 mm, and the thickness of the PTFE layer is 0.03-0.05 mm.

[0014] Furthermore, the overlapping rates of the inner layer and the outer layer are both 50% to 70%.

[0015] Compared to existing technologies, this product offers: 1) high and low temperature resistance, with a temperature range of -100°C to +260°C, effectively meeting the requirements of aviation environments. 2) high mechanical properties: the conductor exhibits excellent tensile strength, over five times that of copper. 3) excellent flexibility and a flex lifespan over ten times that of copper. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a production process flow chart of lightweight and flexible wires using carbon nanotube conductors.

[0017] Figure 2 This is a schematic diagram of the wiring structure.

[0018] Figure 3 It is a schematic diagram of the cable structure.

[0019] In the figure, 1 is the conductor, 2 is the PI / PTFE insulation layer, 3 is the PTFE insulation layer, 4 is the shielding layer, 5 is the FEP / PI composite sheath layer, and 6 is the PTFE sheath layer. DETAILED DESCRIPTION

[0020] Referring to the accompanying drawings, the carbon nanotube conductor lightweight flexible wire has a structure comprising a conductor 1; an insulating layer 2 wrapped around the conductor 1; and an insulating layer 3 wrapped around the insulating layer 2.

[0021] A method for preparing a lightweight and flexible carbon nanotube conductor wire comprises the following steps: 1) Select multiple carbon nanotube twisted fibers and choose the appropriate number for paralleling according to needs; 2) Using a high-precision single-head wrapping machine, wrap a silver-plated (nickel-plated) copper flat wire with a thickness of (0.02±0.008) mm around the carbon nanofiber with a wrapping gap of 0.5% to 1.0% to form a copper / carbon nanotube composite monofilament; 3) Using multiple copper / carbon nanotube composite monofilaments twisted together to form a conductor; 4) Using a wrapping machine, wrap a layer of high-performance PTFE / PI composite tape (0.021-0.027 mm) around the conductor, with an overlap rate of 51%-54%. The number of wrapping layers can be adjusted as needed. A layer of PTFE raw tape (0.030-0.050 mm) is wrapped around the PTFE / PI composite tape, with an overlap rate of 51%-54%. The number of wrapping layers can be adjusted as needed. Ultra-low friction coefficient ceramic wrapping tubes are used to prevent wrinkling of the ultra-thin PTFE tape due to its thinness. Finally, an infrared sintering furnace is used to sinter and shape the tape into a wire.

[0022] 5) Use multiple wires to twist into a cable; 6) Multiple copper / carbon nanotube composite monofilaments are wound side by side on the cable core to form a shield; 7) Using a wrapping machine, wrap a layer of (0.016-0.024) mm high-performance FEP / PI composite tape around the shield, with an overlap ratio of 50%-55%. The number of wrapping layers can be adjusted as needed. Then wrap a layer of (0.030-0.050) mm PTFE raw tape with an overlap ratio of 50%-70%. The number of wrapping layers can be adjusted as needed. Use an ultra-low friction coefficient ceramic wrapping tube to prevent wrinkling caused by the thin thickness of the ultra-thin PTFE tape. Finally, use an infrared sintering furnace to sinter and shape it into a cable.

[0023] Cross-sectional area is 0.35mm 2 The carbon nanotube conductor lightweight flexible wire is made of two twisted carbon nanotube fibers and bundled together. A silver-plated copper flat wire with a thickness of (0.02±0.008) mm is wrapped around the carbon nanofiber bundle with a wrapping gap of 0.5% to 1.0% to form a silver-plated copper / carbon nanotube composite monofilament with a diameter of 0.16 mm. The conductor is twisted by using a wire bundler to twist 19 composite monofilaments into a 19 / 0.16 mm conductor with a twisted pitch ratio of 10 to 12 times. The insulation is wrapped by wrapping a layer of (0 0.021~0.027) mm high-performance PTFE / PI composite tape with an overlap rate of 51%~54%, and then wrapped with a layer of (0.030~0.050) mm PTFE raw tape with an overlap rate of 51%~54%. The wrapping adopts an ultra-low friction coefficient ceramic wrapping tube to prevent the ultra-thin PTFE tape from wrinkling due to its thin thickness; sintering, using a 12-temperature zone infrared sintering furnace for sintering and shaping into wires, the sintering temperature is (300~500) ° C, and the sintering speed is 6~7 m / min.

Claims

1. A carbon nanotube conductor lightweight flexible wire, comprising a conductor and an insulating layer, characterized in that: The conductor is formed by twisting a plurality of copper / carbon nanotube composite monofilaments. The copper / carbon nanotube composite monofilaments are formed by wrapping a copper flat wire around a carbon nanofiber. The carbon nanofiber is formed by twisting a plurality of carbon nanotube fibers together.

2. The carbon nanotube conductor lightweight flexible wire according to claim 1, characterized in that: The copper flat wire is silver-plated or nickel-plated.

3. The carbon nanotube conductor lightweight flexible wire according to claim 2, characterized in that: The thickness of the copper flat wire is 0.020±0.008 mm.

4. The carbon nanotube conductor lightweight flexible wire according to claim 1, characterized in that: The wrapping gap is 0.5% to 1.0%.

5. The carbon nanotube conductor lightweight flexible wire according to claim 1, characterized in that: The insulating layer consists of two layers, the inner layer is a PTFE / PI composite layer, and the outer layer is a PTFE layer.

6. The carbon nanotube conductor lightweight flexible wire according to claim 5, characterized in that: The overlapping rates of the inner layer and the outer layer are both 51% to 54%.

7. The carbon nanotube conductor lightweight flexible wire according to claim 5, characterized in that: The thickness of the PTFE / PI composite layer is 0.021-0.027 mm, and the thickness of the PTFE layer is 0.03-0.05 mm.

8. A lightweight flexible cable with carbon nanotube conductor, characterized in that: The wires of any one of claims 1-5 are twisted into a cable, and a plurality of copper / carbon nanotube composite monofilaments are wound side by side on the cable core to form a shielding layer, the outer layer of the shielding layer is an insulating layer, the inner layer of the insulating layer is a PTFE / PI composite layer, and the outer layer is a PTFE layer.

9. The carbon nanotube conductor lightweight flexible cable according to claim 8, characterized in that: The thickness of the PTFE / PI composite layer is 0.016-0.024 mm, and the thickness of the PTFE layer is 0.03-0.05 mm.

10. The carbon nanotube conductor lightweight flexible cable according to claim 8, characterized in that: The overlapping rates of the inner layer and the outer layer are both 50% to 70%.

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