Cable resistant to high temperature and acid corrosion

Abstract

The invention discloses a cable resistant to high temperature and acid corrosion, and the cable comprises a conductor layer which is formed by concentrically twisting a plurality of nickel-coated copper wires; the inner insulating layer coats the conductor layer and is used for improving the thermal conductivity of the cable; the outer insulating layer is sleeved on the inner insulating layer; the anti-bending buffer layer is coated outside the outer insulating layer; the electromagnetic shielding layer wraps the anti-bending buffer layer and is used for forming a shielding layer; the electromagnetic shielding layer is coated with the anti-corrosion functional layer, the anti-corrosion functional layer is a fluororubber belt, and benzotriazole corrosion inhibition microcapsules are embedded in a rubber layer of the fluororubber belt; and the mechanical strengthening layer is arranged outside the anti-corrosion functional layer in a sleeving manner. According to the invention, the conductor layer adopts the nickel-coated copper wire to improve the high-temperature-resistant conductivity, the corrosion inhibition microcapsules are embedded in the corrosion-resistant functional layer to realize long-acting corrosion resistance, the electromagnetic shielding layer is combined with graphene and the tinned copper strip to enhance the broadband shielding effectiveness, and the cable has long-acting corrosion resistance, mechanical property stability in a high-temperature environment and broadband electromagnetic shielding effectiveness.

Description

Technical Field

[0001] The present invention relates to the technical field of cable structures, in particular to a cable resistant to high temperature and acid corrosion. Background Art

[0002] In heavy industrial fields such as metallurgy and chemical industry, especially in extreme working environments such as copper smelters, cables need to meet multiple stringent performance requirements at the same time.

[0003] Existing cable technology faces three key technical bottlenecks in practical applications. First, mechanical performance degradation in high-temperature environments. Conventional mica tape insulation and steel tape armor structures experience significant softening of the armor layer when subjected to sustained temperatures exceeding 400°C, resulting in a drop in tensile strength of over 40%. Furthermore, due to the excessive structural rigidity, the minimum bend radius must be at least six times the cable's outer diameter, severely limiting its flexibility in mobile devices. Second, there's the issue of passive corrosion protection. When exposed to highly corrosive media such as concentrated sulfuric acid mist, the silicone rubber molecular chains of the current mainstream fluoroplastic and silicone rubber composite sheath rapidly depolymerize, causing surface cracks that expose the internal structural layers and lead to functional failure of the entire cable system within a three-year service life. Finally, there are frequency-band limitations in electromagnetic compatibility performance. Conventional aluminum foil shielding forms a non-conductive oxide layer upon oxidation at high temperatures, resulting in a precipitous drop in shielding effectiveness in the 1kHz-1GHz range. In particular, shielding attenuation exceeds the critical value of 15dB in the low-frequency band.

[0004] These technical defects together make it difficult for existing cable products to meet the complex functional requirements of mechanical strength retention, dynamic bending performance, long-term corrosion resistance and broadband electromagnetic shielding under high temperature and severe corrosion conditions.

[0005] In view of the above problems, the existing technology is in urgent need of improvement. Summary of the Invention

[0006] The purpose of the present invention is to provide a cable that is resistant to high temperature and acid corrosion in order to solve the above-mentioned shortcomings.

[0007] To solve the above technical problems, the present invention adopts the following technical solution: a cable resistant to high temperature and acid corrosion, comprising: The conductor layer is made of multiple nickel-clad copper wires twisted concentrically; An inner insulating layer, covering the conductor layer, to improve the thermal conductivity of the cable; An outer insulating layer is sleeved on the inner insulating layer; A bending buffer layer, covering the outer insulation layer; An electromagnetic shielding layer, covering the anti-bending buffer layer to form a shielding layer; An anti-corrosion functional layer is coated on the outside of the electromagnetic shielding layer, wherein the anti-corrosion functional layer is a fluororubber belt, and the fluororubber belt adhesive layer is embedded with benzotriazole corrosion-inhibiting microcapsules; The mechanical strengthening layer is sleeved outside the anti-corrosion functional layer.

[0008] Furthermore, the conductor layer, inner insulating layer, outer insulating layer, anti-bending buffer layer, electromagnetic shielding layer, anti-corrosion functional layer and mechanical strengthening layer are coaxially arranged.

[0009] Furthermore, the inner insulating layer is woven from mica tape wrapped at a 45° angle; The inner insulating layer further comprises boron nitride ceramic powder filled between the mica tape and the conductor layer.

[0010] Furthermore, the outer insulation layer is made of corrugated PFA fluoroplastic, which is used to compensate for stress when the cable is bent through corrugation expansion and contraction.

[0011] Furthermore, the anti-bending buffer layer is woven from zirconium oxide fibers.

[0012] Furthermore, the electromagnetic shielding layer includes a graphene coating and a tinned copper tape; The tinned copper strip is longitudinally wrapped on the anti-bending buffer layer.

[0013] Furthermore, the mechanical strengthening layer is a stainless steel bellows.

[0014] The beneficial effects of the present invention are embodied in: The present invention provides a cable resistant to high temperature and acid corrosion. The conductor layer uses nickel-clad copper wire to improve high-temperature conductivity, the anti-corrosion functional layer has embedded corrosion-inhibiting microcapsules to achieve long-term corrosion protection, and the electromagnetic shielding layer combines graphene and tinned copper tape to enhance broadband shielding effectiveness. The cable has long-term corrosion protection capability, mechanical performance stability in high-temperature environments, and broadband electromagnetic shielding effectiveness. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 A three-dimensional view of the present invention; Figure 2 It is a structural front view of the present invention.

[0016] In the picture: 1. Conductor layer; 2. Inner insulation layer; 3. Outer insulation layer; 4. Anti-bending buffer layer; 5. Electromagnetic shielding layer; 6. Anti-corrosion functional layer; 7. Mechanical strengthening layer. DETAILED DESCRIPTION

[0017] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. In the absence of conflict, the embodiments in this application and the features in the embodiments can be combined with each other. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0018] In existing technologies, high-temperature, highly corrosive environments such as copper smelters place stringent demands on cable performance, requiring them to simultaneously meet the requirements of high-temperature resistance, corrosion resistance, bending resistance, and electromagnetic shielding. Traditional cables use a combination of mica tape-wrapped insulation and steel tape armored sheaths. The metal armor layer is prone to softening and failure in high-temperature environments above 400°C, and the bending radius is too large to adapt to the needs of mobile devices. Although the composite structure of fluoroplastic and silicone rubber has a certain degree of corrosion resistance, the silicone rubber sheath is prone to aging and cracking in concentrated sulfuric acid mist environments, limiting its service life. When aluminum foil is used as the electromagnetic shielding layer, high-temperature oxidation causes a significant attenuation of shielding effectiveness, and it is unable to cover the entire frequency band from low to high frequencies. These technical defects lead to problems such as insufficient flexibility, passive protection mechanism, and limited shielding bandwidth in cables under high-temperature corrosive conditions.

[0019] In order to solve the above problems, it is first necessary to improve the stability of conductor materials in high-temperature acidic environments. The surface of traditional copper conductors is easily corroded, and the conductivity of pure nickel conductors is insufficient. Secondly, the stress concentration problem caused by high-temperature embrittlement of insulating materials needs to be solved. It is difficult for a single insulating layer to balance thermal conductivity and mechanical properties. In addition, passive anti-corrosion coatings are prone to failure under long-term erosion, and a dynamic protection mechanism needs to be introduced. The electromagnetic shielding layer 5 needs to take into account both electrical conductivity and high-temperature oxidation resistance, while covering broadband interference. By analyzing the synergistic relationship between the various functional layers, it is determined to adopt a layered composite structure to form a gradient protection system on the conductor surface, and to achieve performance breakthroughs through the superposition of material functions and structural optimization.

[0020] Therefore, if Figure 1-2 As shown, the present application proposes a composite structure cable comprising a conductor layer 1, an inner insulating layer 2, an outer insulating layer 3, a bending buffer layer 4, an electromagnetic shielding layer 5, an anti-corrosion functional layer 6, and a mechanical strengthening layer 7. The conductor layer 1 is formed by concentrically twisting multiple nickel-clad copper wires; the inner insulating layer 2 covers the conductor layer 1; the outer insulating layer 3 is sheathed over the inner insulating layer 2; the bending buffer layer 4 covers the outer insulating layer 3; the electromagnetic shielding layer 5 covers the bending buffer layer 4; the anti-corrosion functional layer 6 is a fluororubber tape embedded with benzotriazole corrosion-inhibiting microcapsules; and the mechanical strengthening layer 7 is sheathed over the anti-corrosion functional layer 6.

[0021] Among them, nickel-clad copper wire concentric twisting refers to a structure in which a nickel layer is evenly coated on the surface of the copper wire and then twisted in layers according to a specific twist pitch. The nickel layer can isolate the corrosive medium from contacting the copper core, and the twisted structure enhances the flexibility of the conductor. The specific nickel-clad copper twisted conductor can be composed of 61 single wires with a diameter of 0.20mm and a nickel layer thickness of 0.003mm, which are concentrically twisted.

[0022] The inner insulating layer 2 is made of obliquely wrapped mica tape and filled with boron nitride ceramic powder. The particle size of the boron nitride ceramic powder is 1-3 μm. The oblique weaving of the mica tape provides a stress release channel, and the ceramic powder filling enhances the heat conduction path.

[0023] The outer insulating layer 3 is made of corrugated PFA fluoroplastic. The corrugated structure compensates for bending deformation through axial expansion and contraction. Specifically, the corrugation depth of the outer insulating layer 3 is 0.5 mm and the wave pitch is 8 mm.

[0024] The anti-bending buffer layer 4 is a mesh structure woven from zirconium oxide fibers, which dissipates mechanical stress through sliding friction between fibers. The specifications of the zirconium oxide fiber mesh are ±45° cross-weaving and the density is 60 fibers / cm².

[0025] The electromagnetic shielding layer 5 includes a graphene coating and a tinned copper tape. The graphene provides broadband electromagnetic shielding, and the tinned copper tape enhances conductive continuity. The thickness of the graphene coating is 0.1 mm, and the coverage of the tinned copper tape is above 95%.

[0026] The benzotriazole corrosion inhibition microcapsules in the anti-corrosion functional layer 6 break and release the corrosion inhibitor when corroded by acidic media, thereby forming a dynamic protective film. The particle size of the benzotriazole corrosion inhibition microcapsules is 150-200 μm.

[0027] The mechanical strengthening layer 7 is made of a stainless steel bellows. The corrugated structure allows moderate bending deformation while maintaining mechanical strength. The preferred mechanical strengthening layer 7 is made of SS304 material with a wall thickness of 0.8 mm and a corrugated depth of 3 mm.

[0028] Specifically, the conductor layer 1 utilizes a nickel-copper composite structure to balance electrical conductivity and corrosion resistance. The stranded conductor allows individual filaments to slide relative to each other during bending, preventing breakage. The inner insulation layer 2 features a diagonal mica tape braid that creates a 45-degree stress transfer path. Combined with the high thermal conductivity of the boron nitride ceramic powder, this quickly dissipates heat from the conductor, preventing localized overheating. The corrugated structure of the outer insulation layer 3 allows for axial expansion and contraction when the cable bends, eliminating internal stresses in the insulation material caused by thermal expansion and contraction. The zirconia fibers in the bending buffer layer 4 undergo interlayer displacement when subjected to lateral pressure, converting mechanical energy into heat through friction and dissipating it. The graphene coating in the electromagnetic shielding layer 5 forms a continuous conductive network that absorbs high-frequency electromagnetic waves through multiple reflections, while the tinned copper tape provides a low-frequency current path. The microcapsules in the corrosion-resistant functional layer 6 rupture when acidic media penetrate the fluororubber. The released benzotriazole molecules form a self-assembled monolayer on the metal surface, blocking electrochemical corrosion. The stainless steel bellows in the mechanical reinforcement layer 7 elastically deform when subjected to external impact, absorbing energy while maintaining overall structural integrity.

[0029] Compared with existing technologies, traditional steel tape armored sheaths lose their bending resistance at high temperatures. This solution, through the rigid-flexible combination of a zirconia fiber buffer layer and a stainless steel bellows, maintains effective bending resistance at 600°C. Existing aluminum foil shielding layers lose over 50% shielding effectiveness after oxidation at 300°C. This solution's graphene-tinned copper tape composite shielding layer maintains over 85% shielding effectiveness at 500°C, and covers a frequency range extending from 10kHz to 2GHz. Compared to passively anti-corrosion silicone rubber sheaths, this solution's corrosion-inhibiting microcapsules can continuously release corrosion inhibitors for over 10 years in strong acid environments with a pH <2, forming an active protection mechanism. Traditional corrugated sheaths are mostly made of thermoplastic materials such as PVC. In this solution, the outer insulation layer 3 uses PFA fluoroplastic corrugated tubes, which maintain flexibility while increasing the long-term operating temperature to 260°C. This solution adopts a gradient thermal conductivity design. The combined insulation structure of oblique mica tape and boron nitride ceramic powder can quickly dissipate heat, with a thermal conductivity coefficient of ≥2.5W / m·K. The outer PFA air cavity is insulated, increasing thermal resistance by 40%.

[0030] Through the above technical solutions, this application effectively solves the problem of coordinated optimization of cable flexibility, dynamic protection and electromagnetic shielding in high-temperature corrosion environments. Nickel-clad copper stranded conductors increase the corrosion resistance temperature to 500°C while maintaining conductivity. The combined insulation structure of oblique mica tape and boron nitride ceramic powder increases the thermal conductivity by about 3 times, avoiding insulation aging caused by conductor overheating. The corrugated PFA outer insulation layer 3 reduces the minimum bending radius of the cable to less than 4 times the outer diameter, meeting the wiring requirements of mobile devices. The active release mechanism of benzotriazole corrosion-inhibiting microcapsules increases the service life of the cable from 3 years to more than 10 years in a 50% sulfuric acid mist environment, eliminating the risk of short circuits caused by sheath cracking. The composite shielding layer composed of graphene and tinned copper tape makes the shielding effectiveness in the 1kHz-1GHz frequency band reach more than 90dB, and the high-temperature stability is significantly improved. The stainless steel bellows mechanical reinforcement layer 7 reduces the overall weight of the cable by about 40% while maintaining a compressive strength of ≥200MPa.

[0031] The present application further proposes a coaxial arrangement of the conductor layer 1 , the inner insulating layer 2 , the outer insulating layer 3 , the anti-bending buffer layer 4 , the electromagnetic shielding layer 5 , the anti-corrosion functional layer 6 and the mechanical strengthening layer 7 .

[0032] The coaxial arrangement involves the structural layers being arranged concentrically around the axis of conductor layer 1. This can be achieved using a layered extrusion process coupled with a rotary traction device. By real-time detection of interlayer eccentricity and feedback adjustment of the mold position, the center axes of the layers coincide. This structure eliminates interlayer eccentricity and avoids shear stress concentration caused by radial offset.

[0033] Specifically, the conductor layer 1 serves as the reference for the cable's central axis. The inner insulation layer 2 is wrapped at a 45° angle to form a uniform coating. The outer insulation layer 3 adopts a corrugated structure and extends equidistantly along the axis. The anti-bending buffer layer 4 is braided to provide radial elastic support. The electromagnetic shielding layer 5 is wrapped longitudinally to provide continuous coverage. The anti-corrosion functional layer 6 is spirally wrapped to provide sealing protection. The mechanical reinforcement layer 7 is formed into a bellows to provide axial rigid support. When each layer undergoes thermal expansion or mechanical bending, the corrugated outer insulation layer 3 and the anti-bending buffer layer 4 work together to absorb deformation. The electromagnetic shielding layer 5 and the anti-corrosion functional layer 6 maintain continuous coverage. The mechanical reinforcement layer 7 provides axial constraint, thereby achieving synchronous deformation of each layer and uniform stress distribution.

[0034] Compared with existing technologies, traditional cables with steel-tape armored sheaths experience eccentricity between the metal armor and insulation layers due to manufacturing errors. Differences in thermal expansion coefficients between materials at high temperatures lead to interlayer shear stress, which in turn causes plastic deformation of the sheath. This solution utilizes a coaxial structure to align the thermal expansion directions of each layer, eliminating stress concentration caused by interlayer misalignment. Furthermore, the combined design of the corrugated outer insulation layer (3) and the bend-resistant buffer layer (4) reduces the cable's bending radius to less than 50% of that of traditional structures.

[0035] The present application further proposes that the inner insulating layer 2 is woven from obliquely wrapped mica tapes, and further includes boron nitride ceramic powder filled between the mica tapes and the conductor layer 1 .

[0036] Among them, obliquely wrapped mica tape means that the mica tape is woven in layers at non-orthogonal angles, which can be achieved by wrapping at a 45-degree inclined angle, forming a slippable structure between layers by changing the direction of fiber arrangement.

[0037] Among them, boron nitride ceramic powder refers to a filling material composed of hexagonal boron nitride particles, which can be realized in the form of powder with a particle size of micron level, and a thermal conductive network is formed by filling the gaps in the weaving of mica tape.

[0038] Specifically, the mica tape is wrapped diagonally to form a woven structure with a directional fiber arrangement. This allows for controlled slippage between adjacent mica tape layers when the cable is bent, thereby releasing mechanical stress accumulated within the insulation layer under high-temperature conditions. Boron nitride ceramic powder is filled at the interface between the mica tape and the conductor layer 1, leveraging its high thermal conductivity to establish a longitudinal heat conduction path, rapidly transferring the Joule heat generated by the conductor to the outer heat dissipation structure. Ceramic powder particles are also embedded in the gaps between the mica tape braids, physically strengthening the interlayer bond and preventing thermal expansion at high temperatures that could cause delamination of the insulation layer.

[0039] Compared to existing technologies, traditional mica tape uses an orthogonal wrapping method to create a rigid insulation structure, which is prone to stress concentration and insulation cracking under high-temperature bending conditions. This solution uses diagonal wrapping to form a mesh structure that allows interlayer slippage, giving the insulation layer the ability to adapt to deformation under high temperatures. Compared to solutions that rely solely on the inherent insulation properties of mica tape, the introduction of boron nitride ceramic powder not only improves thermal conductivity but also enhances structural stability through particle filling, overcoming the technical deficiency of weak interlayer bonding in traditional mica tape. Through the above technical solution, the present application realizes the stress release ability of the insulation layer under high-temperature bending conditions, avoiding mechanical damage caused by the rigid structure; enhances the longitudinal thermal conductivity of the insulation layer, and reduces the impact of the conductor temperature rise on the material properties; and maintains the integrity and dielectric strength of the insulation layer under high-temperature environments through the dense composite structure formed by particle filling.

[0040] The present application further proposes that the outer insulation layer 3 is made of corrugated PFA fluoroplastic, and the stress when the cable is bent is compensated by the expansion and contraction of the corrugations.

[0041] Corrugated PFA fluoroplastic refers to an insulation layer with a continuous wavy surface structure formed by extrusion of a perfluoroalkoxy polymer material. This can be achieved by using a compression molding process to form periodic corrugations with a peak height of 0.5-1.2 mm on the insulation layer's surface. This structure is capable of elastic deformation when subjected to stress. Corrugation expansion compensation utilizes the geometric deformability of the corrugated structure. This can be achieved by setting the ratio of the axial spacing of the corrugations to the peak height to be between 3:1 and 5:1. This allows the outer insulation layer 3 to absorb internal stress through compression or expansion of the corrugations when the cable bends.

[0042] Specifically, the corrugated structure forms an elastic deformation space through periodic undulations of crests and troughs. When the cable is subjected to bending forces, the crest spacing of the corrugations dynamically adjusts according to the direction of the force. The corrugation spacing on the outside of the bend is stretched and expanded, while the corrugation spacing on the inside of the bend is compressed and reduced. This bidirectional deformation mechanism enables the insulation layer to effectively absorb the stress generated by the displacement difference between the conductor layer 1 and the sheath layer. While maintaining its heat resistance of 260°C, PFA fluoroplastic has an elongation at break of over 300%, ensuring that the corrugated structure maintains sufficient deformation capacity in high-temperature environments. The axial arrangement of the corrugations is orthogonal to the cable bending direction, further optimizing the stress release path.

[0043] Compared to existing technologies, conventional steel-tape armored sheaths lose their stress-relieving capabilities due to material softening at high temperatures. However, the corrugated PFA fluoroplastic insulation layer actively absorbs stress through structural deformation, eliminating the need for plastic deformation. Compared to conventional flat-wall fluoroplastic insulation, the corrugated structure disperses bending stress across multiple wave crests, preventing excessive stress concentration in a single location. The brittleness of existing aluminum foil shielding layers due to oxidation is eliminated with PFA, and the corrugated structure itself does not produce metal fatigue.

[0044] Through the above technical solution, this application reduces the cable's minimum bending radius to less than three times its outer diameter under high-temperature conditions, while maintaining the structural integrity of the outer insulation layer 3 under 10% axial strain. The corrugated structure reduces the risk of insulation cracking under frequent bending conditions, and the PFA material ensures the long-term effectiveness of the stress compensation function in highly acidic environments. The improved overall flexibility of the cable enables it to meet the continuous operation requirements of mobile equipment in smelters.

[0045] The present application further proposes that the anti-bending buffer layer 4 is woven from zirconium oxide fibers.

[0046] Zirconia fibers are inorganic fibers made from zirconium oxide ceramics. These fibers are produced using a sol-gel method to create continuous, long fibers. Their crystal structure remains stable at high temperatures. The mesh structure formed by weaving zirconium oxide fibers achieves stress buffering through the distribution of interfiber spaces, and the relative sliding between fibers disperses localized stress concentrations.

[0047] Specifically, the high melting point of zirconia fiber enables it to maintain mechanical strength in environments above 400°C, avoiding the deterioration in bending resistance caused by the high-temperature softening of traditional metal materials. The topological characteristics of the fiber braid structure allow deformation energy to be absorbed through fiber displacement when the cable bends, while its low thermal conductivity reduces heat transfer to the internal insulation layer. In acidic corrosive environments, the chemical inertness of zirconia fiber resists erosion by concentrated sulfuric acid mist, preventing structural damage to the braid layer caused by corrosion.

[0048] Compared to existing technologies, traditional steel armor layers are prone to plastic deformation at high temperatures, resulting in an increased bending radius. Zirconia fiber braids, however, utilize the high-temperature resistance of inorganic fibers to avoid softening failure. Compared to the rigid structure of metal armor, the flexible topology of the fiber braid allows for dynamic stress release, resolving the conflict between material embrittlement and stress concentration in high-temperature environments.

[0049] Through the above technical solution, the present application achieves structural stability of the cable's flexural buffer layer 4 in high-temperature, acidic environments. The fiber displacement mechanism absorbs bending stress, preventing degradation of flexural performance due to high-temperature softening. The chemical inertness of zirconia fibers further ensures the long-term reliability of the buffer layer in corrosive media, addressing the failure of traditional metal materials under the combined conditions of high temperature and corrosion.

[0050] The present application further proposes that the electromagnetic shielding layer 5 includes a graphene coating and a tinned copper tape, and the tinned copper tape is longitudinally wrapped around the anti-bending buffer layer 4.

[0051] Among them, the graphene coating refers to a continuous conductive film formed on the surface of the anti-bending buffer layer 4 through a chemical vapor deposition process. Specifically, it can be achieved by using a single layer of graphene with a thickness of 5-10 nanometers. Its hexagonal lattice structure can form a three-dimensional conductive network. Among them, the tinned copper strip refers to a tin coating with a thickness of 2-5 microns formed on the surface of the copper strip by a hot dip plating process. Specifically, it can be achieved by using a pure tin plating solution with a tin content of 99.9%. The tin coating can isolate oxygen from contact with the copper substrate. Among them, longitudinal wrapping refers to spiral wrapping along the axial direction of the cable with an overlap rate of 15-25%. Specifically, it can be achieved by using automatic wrapping equipment with a tension control of 5-8N. The gaps between the directionally arranged metal strips form electromagnetic wave reflection channels.

[0052] Specifically, by combining a composite shielding structure of graphene coating and tinned copper tape, a dual electromagnetic protection mechanism is formed during cable operation. The two-dimensional planar structure of graphene forms a continuous conductive layer on the surface of the anti-bending buffer layer 4, absorbing 1kHz-1GHz high-frequency electromagnetic wave energy through free electron oscillation. The tinned copper tape attenuates 10kHz-100MHz low-frequency electromagnetic interference through the eddy current effect generated by the metal conductor. The tin coating on its surface preferentially oxidizes in a high-temperature acidic environment to form a dense oxide film, preventing further corrosion of the copper substrate. The longitudinal wrapping process maintains a constant contact pressure between the tinned copper tape and the anti-bending buffer layer 4, and the gap between the metal tapes forms a directional electromagnetic wave reflection path, enhancing the shielding effectiveness through multiple reflections.

[0053] Compared to existing technologies, traditional aluminum foil shielding undergoes grain boundary oxidation above 400°C, resulting in a decrease in conductivity. However, the tin coating on tinned copper tape forms a stable tin oxide protective layer at the same temperature. A single aluminum foil shield can only reflect electromagnetic waves in the 300kHz-100MHz frequency range, while the composite structure of graphene and tinned copper tape can cover the full frequency range of 1kHz-1GHz. Aluminum foil shielding is prone to cracking when bent, leading to shielding failure. The longitudinal wrapping process allows the tinned copper tape to maintain structural integrity by adjusting the gap when the cable is bent.

[0054] Through the above technical solution, this application effectively suppresses the propagation of high- and low-frequency electromagnetic interference in high-temperature, acidic environments, slows the oxidation of the shielding layer's metal material, and ensures the stability of the cable's electromagnetic shielding effectiveness during continuous operation in a 400°C concentrated sulfuric acid mist environment. The composite shielding structure achieves full-band interference protection through dual absorption and reflection mechanisms. The longitudinal wrapping process improves the shield's resistance to mechanical stress, and the tinning treatment enhances the copper tape's durability in corrosive media.

[0055] The present application further proposes that the mechanical strengthening layer 7 is a stainless steel bellows.

[0056] Stainless steel bellows are tubular components with a continuous corrugated structure made from austenitic stainless steel. Specifically, the corrugated structure can be achieved using SUS316L stainless steel through a hydroforming process. This material maintains stable mechanical properties in high-temperature environments, preventing the softening and deformation of traditional steel belt armor at temperatures above 400°C. The periodic undulating geometry of the corrugated structure absorbs stress through corrugated deformation when the cable bends, reducing overall bending stiffness.

[0057] Specifically, when the stainless steel bellows serves as the mechanical reinforcement layer 7, its annular corrugated structure allows the cable to undergo elastic deformation during axial compression or radial bending, thereby dispersing the stress concentration caused by external loads. Under high-temperature conditions, the solid solution strengthening effect of austenitic stainless steel maintains the tensile strength of the bellows, while the geometric characteristics of the corrugated structure itself reduce the cable's bending radius. Compared to the flat, rigid structure of traditional steel tape armor, the bellows release bending stress through deformation while maintaining radial support for the internal structure, achieving a balance between mechanical protection and flexibility.

[0058] Compared to existing technologies, traditional steel tape armor uses a flat steel tape spirally wound to form a rigid sheath. At high temperatures, the material's yield strength decreases, causing the sheath to collapse and fail, and the bending radius must be at least six times the cable's outer diameter. Stainless steel bellows, on the other hand, leverages the synergistic effect of its heat resistance and structural flexibility to maintain the sheath's structural integrity at the same temperature and reduce the bending radius to within three times the cable's outer diameter, without sacrificing compressive strength. Through the above technical solution, this application solves the problem of mechanical protection failure caused by the softening of the metal sheath in a high-temperature environment. The deformation ability of the corrugated tube structure enables the cable to adapt to the frequent bending requirements of mobile equipment. While maintaining a compressive strength of not less than 30 MPa, the minimum bending radius is reduced from 120 mm in the traditional solution to 60 mm, meeting the cable flexibility requirements of mobile equipment in copper smelters.

[0059] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), such directional indications are only used to explain the relative position relationship, movement status, etc. between the various components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0060] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features specified as "first" and "second" may explicitly or implicitly include at least one of such features. In addition, the technical solutions between the various embodiments can be combined with each other, but this must be based on the fact that ordinary technicians in this field can implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0061] In addition, "plurality" means two or more.

[0062] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A cable resistant to high temperature and acid corrosion, characterized in that: include: The conductor layer (1) is formed by concentrically twisting a plurality of nickel-clad copper wires; An inner insulating layer (2) coated on the conductor layer (1) to improve the thermal conductivity of the cable; An outer insulating layer (3) is sleeved on the inner insulating layer (2); A bending-resistant buffer layer (4) is coated on the outside of the outer insulating layer (3); An electromagnetic shielding layer (5) is coated on the outside of the anti-bending buffer layer (4) to form a shielding layer; An anti-corrosion functional layer (6) is coated on the outside of the electromagnetic shielding layer (5), wherein the anti-corrosion functional layer (6) is a fluororubber belt, and the fluororubber belt adhesive layer is embedded with benzotriazole corrosion-inhibiting microcapsules; The mechanical strengthening layer (7) is sleeved outside the anti-corrosion functional layer (6).

2. The cable resistant to high temperature and acid corrosion according to claim 1, characterized in that: The conductor layer (1), the inner insulating layer (2), the outer insulating layer (3), the anti-bending buffer layer (4), the electromagnetic shielding layer (5), the anti-corrosion functional layer (6) and the mechanical strengthening layer (7) are coaxially arranged.

3. The cable resistant to high temperature and acid corrosion according to claim 2, characterized in that: The inner insulating layer (2) is woven from mica tape wrapped at a 45° angle; The inner insulating layer (2) also includes boron nitride ceramic powder filled between the mica tape and the conductor layer (1).

4. The cable resistant to high temperature and acid corrosion according to claim 2, characterized in that: The outer insulating layer (3) is made of corrugated PFA fluoroplastic, and is used to compensate for stress when the cable is bent through corrugation expansion and contraction.

5. The cable resistant to high temperature and acid corrosion according to claim 4, characterized in that: The anti-bending buffer layer (4) is woven from zirconium oxide fibers.

6. The cable resistant to high temperature and acid corrosion according to claim 1, characterized in that: The electromagnetic shielding layer (5) comprises a graphene coating and a tinned copper strip; The tinned copper strip is longitudinally wrapped on the anti-bending buffer layer (4).

7. The cable resistant to high temperature and acid corrosion according to claim 1, characterized in that: The mechanical strengthening layer (7) is a stainless steel bellows.

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