Corrosion-resistant composite cable and preparation method thereof

Abstract

The invention provides a corrosion-resistant composite cable and a preparation method thereof, the corrosion-resistant composite cable comprises a signal unit, an optical cable unit and a protection unit, the signal unit and the optical cable unit are coated with the protection unit, the signal unit comprises a silver-plated copper conductor, an insulating layer, a shielding layer and a sheath layer, and the silver-plated copper conductor is coated with the insulating layer. The optical cable unit comprises an optical fiber, a buffer tube and a filler; the protection unit comprises an inner sheath, a tensile layer, an anti-corrosion layer and an outer sheath. The corrosion-resistant composite cable has good corrosion resistance, can effectively resist corrosion of various chemical substances, prolongs the service life of the cable, reduces the fault risk caused by corrosion, and improves the stability and reliability of power transmission or signal transmission; under severe environment conditions, such as high humidity, high salinity and high alkalinity, a normal working state can still be kept, continuous and stable support is provided for related equipment or systems, and normal operation of the equipment or systems is guaranteed.

Description

Technical Field

[0001] The present application relates to the technical field of communication cables, and in particular to a corrosion-resistant composite cable and a preparation method thereof. Background Art

[0002] A high-salt, high-humidity environment refers to the corrosion experienced by objects exposed to conditions of high salt concentration and high humidity. High-humidity and high-salt environments also exist in some production equipment in the chemical, metallurgical, and salt-making industries. In such corrosive environments, salt adheres to metal surfaces and absorbs water, forming an electrolyte solution. This leads to electrochemical reactions during the corrosion process, accelerating metal oxidation and corrosion. The corrosion rate of metal materials in such environments can be significantly increased, especially when exposed to high temperatures or humidity. Common forms of corrosion in such environments include general corrosion, pitting corrosion, stress corrosion cracking, and marine corrosion. It is particularly important to note that high-salt, high-humidity environments can pose a serious corrosion threat to equipment, structures, and materials, particularly metal materials. Therefore, equipment and cables operating in such environments require special control measures to slow the corrosion rate of the materials. Furthermore, existing optoelectronic composite cables are not very waterproof or corrosion-resistant, resulting in poor applicability.

[0003] Existing optoelectronic composite cables consist of optical fibers, cable cores, and protective layers. In conventional circular optoelectronic composite cables, the core is composed of optical fibers covered with a protective layer, conductors covered with an insulation layer, and filler ropes twisted around a central reinforcement. The core is covered with a sheath to protect the cable from corrosion. Common sheath materials used in current optoelectronic composite cables include polyolefin, polyvinyl chloride, and polyurethane. Polyolefin sheath has good mechanical strength and chemical resistance, and after cross-linking modification, its operating temperature can reach 150°C, it has low water absorption and excellent electrical insulation, but its heat aging resistance and corrosion resistance are poor, and its low temperature resistance and wear resistance are average; polyurethane sheath has high strength and toughness, and has excellent wear resistance, high temperature resistance, flame retardancy and chemical corrosion resistance, but it is brittle and easy to break, has poor heat resistance under high temperature conditions, and is easily corroded by chemicals such as methanol, water, ultraviolet rays, concentrated acids and alkalis, which affects its service life; therefore, it is necessary to develop a waterproof and corrosion-resistant optoelectronic composite cable with high strength, good toughness, high temperature resistance and aging resistance, so that it can solve the problem of corrosion resistance in salt mine environment while also making the optoelectronic composite cable have excellent comprehensive performance.

[0004] Invention patent CN201310401119.5 discloses a highly flexible insulating sheath material for transformers, the components of which are: This patent can withstand long-term bending movement, has extremely excellent tensile properties, and also has excellent heat resistance, weather resistance, acid and alkali corrosion resistance, electrical insulation, tear strength and other properties. However, the waterproofness of the insulating sheath material is average, and its corrosion resistance to some special chemical substances (such as methanol, concentrated acid and alkali, etc.) is average, which affects the service life and use environment of the sheath material. Summary of the Invention

[0005] This application is made in view of the above problems, and its purpose is to provide a corrosion-resistant composite cable and a preparation method thereof, so as to increase the service life of the cable material in a salt mine environment.

[0006] Specifically as follows, a first aspect of the present application provides a corrosion-resistant composite cable, comprising a signal unit, an optical cable unit, and a protective unit, wherein the protective unit is coated on the outside of the signal unit and the optical cable unit; The signal unit includes a silver-plated copper conductor, an insulating layer, a shielding layer and a sheath layer, and the protection unit includes an anti-corrosion layer.

[0007] Furthermore, the surface of the silver-plated copper conductor is coated with a graphene layer; and / or The insulating layer is cross-linked polyethylene.

[0008] Furthermore, the shielding layer includes a tinned copper wire braid and a nano-alumina modified aluminum foil wrapping.

[0009] Furthermore, the sheath layer comprises the following components in parts by mass: 40-55 parts of EPDM rubber, 25-35 parts of polyurethane, 5-8 parts of fumed silica, 3-5 parts of boron nitride nanosheets, 2-4 parts of perfluoropolyether oil, 0.8-1.2 parts of vulcanizing agent, and 0.1-0.4 parts of accelerator.

[0010] Furthermore, the optical cable unit includes an optical fiber, a buffer tube and a filler; The optical fiber is embedded in a buffer tube and filled with a filler; and / or The buffer tube is a fluororesin tube; and / or The filler is hydrogenated nitrile gel.

[0011] Furthermore, the protective unit comprises an inner sheath, a tensile layer and an outer sheath; The tensile layer is a mixed weave of aramid fibers and carbon fibers; and / or The inner and outer sheaths contain an antistatic agent and a flame retardant. The antistatic agent comprises the following components in parts by mass: 1-2 parts of carbon nanotubes, 0.5-1 parts of ionic liquid [BMIM]PF, and 0.1-0.5 parts of a dispersant; and / or the flame retardant is a brominated flame retardant or a halogen-free flame retardant.

[0012] Furthermore, the anti-corrosion layer includes 1-2 parts of tribasic lead sulfate and 3-5 parts of chlorinated paraffin.

[0013] A second aspect of the present application provides a method for preparing the corrosion-resistant composite cable, comprising the following steps: S1: Composite manufacturing of signal unit, which uses co-extrusion die to extrude conductor insulation layer and shielding layer simultaneously, and then coat with sheath layer; S2: Optical cable unit packaging, hydrogenated nitrile gel perfusion; S3: Co-extrusion vulcanization of protective unit, using twin-screw extrusion; S4: Electron beam post-processing to improve material crystallinity.

[0014] Furthermore, the hydrogenated butadiene nitrile gel perfusion includes glue injection and curing, wherein the glue injection is performed by hot pressing and packaging under a nitrogen environment of 0.05 MPa; and / or The curing includes a first stage, a second stage and a third stage, The curing temperature of the first stage is 75-85°C and the curing time is 0.5-1.5h; and / or The curing temperature of the second stage is 110-130° C. and the curing time is 1.5-2.5 hours; and / or The curing temperature of the third stage is 140-160° C., and the curing time is 0.5-1.5 hours.

[0015] Furthermore, the irradiation dose of the electron beam is 15-20 kGy.

[0016] The present invention has the following beneficial effects: (1) The corrosion-resistant composite cable of the present invention comprises a signal unit, an optical cable unit and a protective unit. The signal unit is composed of a silver-plated copper conductor, an insulation layer, a shielding layer and a sheath layer. The silver-plated copper conductor has good electrical conductivity and corrosion resistance. The silver coating can effectively resist environmental erosion on the copper conductor, ensuring stable current transmission. The insulation layer isolates the silver-plated copper conductor from the outside world to prevent current leakage and ensure safe use. The shielding layer can shield external electromagnetic interference and improve the accuracy of cable transmission signals. The sheath layer plays a mechanical role in protecting the internal structure and enhancing the durability of the cable.

[0017] The optical cable unit includes an optical fiber, a buffer tube, and a filler. The optical fiber is used for optical signal transmission, has the characteristics of high bandwidth and low loss, and can achieve high-speed data transmission; the buffer tube protects the optical fiber from external mechanical stress, preventing the optical fiber from being damaged by bending, stretching, etc.; the filler is filled between the buffer tube and other structures, playing a buffering and moisture-proof role, ensuring a stable working environment for the optical fiber.

[0018] The protective unit consists of an inner sheath, a tensile layer, an anti-corrosion layer and an outer sheath, wherein the inner sheath further wraps and protects the signal unit and the optical cable unit to prevent damage caused by mutual friction between the internal structures; the tensile layer enhances the overall tensile strength of the cable, making the cable less likely to break during stretching and adapting to different installation environments; the anti-corrosion layer resists corrosion to the cable by various chemicals, moisture and other environmental factors, thereby extending the service life of the cable; the outer sheath, as the outermost protective structure of the cable, provides additional mechanical protection and environmental protection, prevents external objects from causing physical damage to the cable, and resists the influence of environmental factors such as ultraviolet rays. (2) The corrosion-resistant composite cable of the present invention has good corrosion resistance, can effectively resist the erosion of various chemical substances, extend the service life of the cable, reduce the risk of failure due to corrosion, and improve the stability and reliability of power transmission or signal transmission; under harsh environmental conditions, such as high humidity, high salinity and other environments, it can still maintain normal working state, provide continuous and stable support for related equipment or systems, and ensure their normal operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the embodiments of the present drawings or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present drawings. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying any creative work.

[0020] Figure 1 It is a schematic cross-sectional view of the corrosion-resistant composite cable of the present invention.

[0021] Explanation of the accompanying reference numerals: 10. Signal unit; 20. Optical cable unit; 30. Protection unit; 11. Silver-plated copper conductor; 12. Insulation layer; 13. Shielding layer; 14. Sheath layer; 21. Optical fiber; 22. Buffer tube; 23. Filler; 31. Inner sheath; 32. Tensile layer; 33. Anti-corrosion layer; 34. Outer sheath.

[0022] The purpose, features and advantages of this drawing will be further described with reference to the accompanying drawings in conjunction with the embodiments. DETAILED DESCRIPTION

[0023] In order to make the purpose, technical solutions and advantages of this application more clearly understood, the present application is described and illustrated below in conjunction with the embodiments. It should be understood that the specific embodiments described herein are merely used to explain this application and are not intended to limit this application. Based on the embodiments provided in this application, all other embodiments obtained by those of ordinary skill in the art without making any creative work are within the scope of protection of this application.

[0024] Obviously, the following descriptions are merely some examples or embodiments of the present application. Those skilled in the art can apply the present application to other similar scenarios without inventive effort. Furthermore, it is also understood that, although the effort involved in such a development process may be complex and lengthy, for those skilled in the art related to the content disclosed in the present application, changes in design, manufacturing, or production based on the technical content disclosed in the present application are merely conventional technical means and should not be construed as an insufficiency of the content disclosed in the present application.

[0025] Unless otherwise specified, the terms "include" and "comprising" used in this application may be open-ended or closed-ended. For example, "include" and "comprising" may mean that other components not listed may also be included or that only the listed components are included.

[0026] A first aspect of the present application provides a corrosion-resistant composite cable, comprising a signal unit 10, an optical cable unit 20 and a protective unit 30, wherein the protective unit 30 is coated on the outside of the signal unit 10 and the optical cable unit 20, the signal unit 10 comprising a silver-plated copper conductor 11, an insulating layer 12, a shielding layer 13 and a sheath layer 14, the optical cable unit 20 comprising an optical fiber 21, a buffer tube 22 and a filler 23; the protective unit 30 comprising an inner sheath 31, a tensile layer 32, an anti-corrosion layer 33 and an outer sheath 34.

[0027] The corrosion-resistant composite cable of the present invention comprises a signal unit 10, an optical cable unit 20, and a protective unit 30. The signal unit 10 is composed of a silver-plated copper conductor 11, an insulation layer 12, a shielding layer 13, and a sheath layer 14. The silver-plated copper conductor 11 has excellent conductivity and corrosion resistance. The silver coating effectively protects the copper conductor from environmental corrosion, ensuring stable current transmission. The insulation layer 12 isolates the silver-plated copper conductor 11 from the outside world, preventing current leakage and ensuring safe use. The shielding layer 13 shields against external electromagnetic interference, improving the accuracy of cable transmission signals. The sheath layer 14 provides mechanical protection for the internal structure and enhances the durability of the cable.

[0028] The optical cable unit 20 includes an optical fiber 21, a buffer tube 22 and a filler 23. The optical fiber 21 is used for optical signal transmission, has the characteristics of high bandwidth and low loss, and can achieve high-speed data transmission; the buffer tube 22 protects the optical fiber 21 from external mechanical stress, preventing the optical fiber 21 from being damaged by bending, stretching, etc.; the filler 23 is filled between the buffer tube 22 and other structures, playing a buffering and moisture-proof role, ensuring a stable working environment for the optical fiber 21.

[0029] The protective unit 30 is composed of an inner sheath 31, a tensile layer 32, an anti-corrosion layer 33 and an outer sheath 34, wherein the inner sheath 31 further wraps and protects the signal unit 10 and the optical cable unit 20 to prevent damage to the internal structures by friction with each other; the tensile layer 32 enhances the overall tensile strength of the cable, making the cable less likely to break during the stretching process and adapting to different installation environments; the anti-corrosion layer 33 resists corrosion of the cable by various chemicals, moisture and other environmental factors, thereby extending the service life of the cable; the outer sheath 34, as the outermost protective structure of the cable, provides additional mechanical protection and environmental protection to prevent external objects from causing physical damage to the cable and resist the influence of environmental factors such as ultraviolet rays. In this embodiment, the surface of the silver-plated copper conductor 11 is coated with a graphene layer. The preparation method of the silver-plated copper conductor 11 is as follows: placing the silver-plated copper conductor 11 in a reaction device, introducing methane gas, and controlling the temperature to 600-1000° C. and the pressure to 0.1-10 kPa in an argon / hydrogen mixed atmosphere to decompose carbon atoms on the surface and form a graphene layer.

[0030] The insulating layer 12 is made of cross-linked polyethylene.

[0031] In this embodiment, the shielding layer 13 comprises a tinned copper wire mesh wrapped with nano-alumina-modified aluminum foil. The tinned copper wire mesh was purchased from Anping Guanwo Wire Mesh Products Co., Ltd., while the nano-alumina-modified aluminum foil was purchased from Dongguan Nianbang Aluminum Co., Ltd. The nano-alumina-modified aluminum foil is a composite shielding material made from nano-alumina film and aluminum foil, enhancing wear resistance, oxidation resistance, and thermal conductivity.

[0032] In this embodiment, the sheath layer 14 includes the following components in parts by mass: 40-55 parts of EPDM rubber, 25-35 parts of polyurethane, 5-8 parts of fumed silica, 3-5 parts of boron nitride nanosheets, 2-4 parts of perfluoropolyether oil, 0.8-1.2 parts of vulcanizing agent, and 0.1-0.4 parts of accelerator.

[0033] In another embodiment of the present invention, the jacket layer 14 is prepared by placing EPDM rubber and polyurethane into an internal mixer, setting the mixer temperature to 100-120°C and the speed to 30-50 r / min, and mixing for 5-8 minutes to achieve a preliminary uniform mixing of the EPDM rubber and polyurethane to form a basic mixture; sequentially adding fumed silica and boron nitride nanosheets, and continuing to mix for 5-7 minutes; adding perfluoropolyether oil, a dipentadienyl vulcanizer, and a TMTD accelerator, lowering the internal mixer temperature to 80-90°C, adjusting the speed to 20-30 r / min, and mixing for 8-10 minutes. The mixed materials are transferred to an open mixer, adjusting the roller gap to 2-3 mm, and thinning the materials 5-8 times at 50-60°C to further uniformly mix the materials; and placing the formed jacket layer 14 into an autoclave for vulcanization treatment at 150-170°C and a pressure of 1-1.5 MPa for 10-15 minutes.

[0034] EPDM rubber has excellent weather resistance, ozone resistance, chemical resistance, good flexibility, and electrical insulation. As the primary elastomer in the sheath layer, it provides basic physical properties, ensuring the sheath can adapt to different environmental conditions and resist external corrosion. It also has certain tensile and bending properties, protecting the internal structure from external forces.

[0035] Polyurethane has a hardness of 85A and is characterized by high strength, abrasion resistance, oil resistance, and good adhesion. Combined with EPDM rubber, it enhances the overall strength and abrasion resistance of the sheath, allowing it to better protect the interior in environments where friction and scratches may occur.

[0036] Fumed silica has thickening, thixotropic, and reinforcing properties. In the jacket layer 14, it increases the material's viscosity, improves processing performance, and prevents sagging during the molding process. It also reinforces the rubber matrix, improving the jacket's tensile strength, tear strength, and other mechanical properties.

[0037] Boron nitride nanosheets have high thermal conductivity, good electrical insulation, and certain mechanical strengthening properties. In the jacket layer 14, they can effectively improve the thermal conductivity of the material, allowing the heat generated during use of the jacket to be quickly dissipated, avoiding performance degradation due to overheating.

[0038] Perfluoropolyether oil has excellent chemical stability, a low coefficient of friction, and good lubrication properties. When used in sheaths, it reduces friction between the material's components, improving processing fluidity and making the production process smoother. Furthermore, during use, it reduces frictional losses when the sheath contacts other objects, extending the sheath's service life.

[0039] The vulcanizing agent is a dipentadiene vulcanizing agent, which crosslinks rubber molecules, forming a three-dimensional network structure, thereby improving the rubber's strength, hardness, and wear resistance. The vulcanizing agent content is 0.8-1.2 parts. Too little crosslinking will not fully enhance performance, while too much may cause the rubber to become too hard and brittle, losing its elasticity and flexibility.

[0040] The accelerator is TMTD, which can accelerate the vulcanization reaction, reduce the vulcanization temperature, shorten the vulcanization time, and improve the physical and mechanical properties of the vulcanized rubber.

[0041] In this embodiment, the optical fiber 21 in the optical cable unit 20 is embedded in a buffer tube 22 and filled with a filler 23; the buffer tube 22 is a fluororesin tube, and the filler 23 is hydrogenated nitrile gel. The hydrogenated nitrile gel provides a buffer for the optical fiber 21 embedded in the buffer tube 22, reducing physical damage to the optical fiber 21 caused by external factors such as vibration and impact, ensuring the structural integrity of the optical fiber 21 and maintaining its normal signal transmission function. The hydrogenated nitrile gel can fill the gaps within the buffer tube 22 to form a good sealing environment, preventing external moisture from intruding and preventing moisture from corroding the optical fiber 21, thereby extending the service life of the optical fiber 21. The hydrogenated nitrile gel can maintain good performance over a wide temperature range, allowing the optical fiber 21 to continue to operate stably under different temperature conditions and reducing performance fluctuations caused by temperature changes. The hydrogenated nitrile gel is chemically compatible with the optical fiber 21 and the fluororesin material of the buffer tube 22, and will not chemically react with them, ensuring the long-term stability of the entire optical cable unit 20 system. The hydrogenated nitrile gel comprises 100 parts of hydrogenated nitrile rubber (HNBR), 15 parts of white carbon black, and 0.5 parts of a hydrogen inhibitor (PdCl2). The preparation method comprises the following steps: first, adding the hydrogenated nitrile rubber (HNBR) into a reactor, setting the temperature to 60-70°C, and stirring to melt; after the hydrogenated nitrile rubber is completely melted, slowly adding 15 parts of white carbon black, and continuously stirring for 20-30 minutes to ensure that the white carbon black is evenly dispersed in the rubber system; then, dissolving 0.5 parts of the hydrogen inhibitor (PdCl2) in 30 ml of acetone, ultrasonically treating (40 kHz, 30 minutes) to form a nanoscale colloidal solution, and adding the solution dropwise into the reactor, continuing to stir and react for 1-2 hours; after the reaction is completed, removing the mixture from the reactor, pouring it into a mold, and vulcanizing and molding it at 160-170°C for 2 hours to obtain the hydrogenated nitrile gel. In hydrogenated nitrile gel, nitrile rubber serves as the base rubber material, providing essential rubber properties such as elasticity and flexibility. It is the primary component of the gel structure. Silica serves primarily as a reinforcing filler. It enhances the mechanical properties of hydrogenated nitrile gel, such as strength and hardness, while also improving its wear resistance and tear resistance. By interacting with rubber molecules, it is evenly dispersed throughout the rubber system, enhancing the rubber's overall performance. The hydrogen inhibitor, PdCl2, acts to hinder hydrogen-related reactions. In some applications, hydrogen may adversely affect the performance of rubber materials, such as accelerated aging. Hydrogen inhibitors, through their chemical action, inhibit the reaction between hydrogen and rubber, thereby extending the material's service life and maintaining its performance stability.

[0042] Hydrogenated nitrile gel combines the rubber properties of HNBR, the reinforcing and filling benefits of silica, and the hydrogen barrier properties of a hydrogen inhibitor. In practical applications, it exhibits excellent elasticity and flexibility, allowing it to adapt to a certain degree of deformation. It also possesses high strength, hardness, wear resistance, and tear resistance, making it suitable for applications requiring high mechanical properties.

[0043] In this embodiment, the tensile layer 32 is a mixed weave of aramid fibers and carbon fibers. The aramid fibers have high strength, high modulus, and good toughness, while the carbon fibers have properties such as high strength, low density, and high temperature resistance. When the aramid fibers and carbon fibers are mixed and woven to form the tensile layer 32, the advantages of both can be combined. On the one hand, the toughness of the aramid fibers can absorb part of the energy when the material is subjected to tensile force, thereby preventing the material from failing due to brittle fracture. On the other hand, the high strength and low density of the carbon fibers can ensure that the tensile layer 32 has strong tensile strength while reducing its own weight as much as possible, thereby alleviating the burden on the overall structure. In this embodiment, the material of the inner sheath 31 and the outer sheath 34 is substantially the same as that of the sheath layer 14. Based on the material of the sheath layer 14, the inner sheath 31 and the outer sheath 34 contain an antistatic agent and a flame retardant. The antistatic agent comprises the following components in parts by mass: 1-2 parts of carbon nanotubes, 0.5-1 parts of ionic liquid [BMIM]PF, and 0.1-0.5 parts of a dispersant; the flame retardant is 1-2 parts of a brominated flame retardant or 1-2 parts of a halogen-free flame retardant.

[0044] In this embodiment, the anti-corrosion layer 33 includes 1-2 parts of tribasic lead sulfate and 3-5 parts of chlorinated paraffin.

[0045] A second aspect of the present application provides a method for preparing the corrosion-resistant composite cable, comprising the following steps: S1: Composite manufacturing of signal unit, which uses co-extrusion die to extrude conductor insulation layer and shielding layer simultaneously, and then coat with sheath layer; S2: Optical cable unit packaging, hydrogenated nitrile gel perfusion; S3: Co-extrusion vulcanization of protective unit, using twin-screw extrusion; S4: Electron beam post-processing to improve material crystallinity.

[0046] In this embodiment, the hydrogenated nitrile gel perfusion includes glue injection and curing, wherein the glue injection is hot pressing and packaging under a nitrogen environment of 0.05 MPa; the curing includes a first stage, a second stage and a third stage. The curing temperature of the first stage is 75-85°C and the curing time is 0.5-1.5h; The curing temperature of the second stage is 110-130°C and the curing time is 1.5-2.5h; The curing temperature of the third stage is 140-160° C., and the curing time is 0.5-1.5 hours.

[0047] In this embodiment, the irradiation dose of the electron beam is 15-20 kGy.

[0048] Example 1 A corrosion-resistant composite cable comprises a signal unit, an optical cable unit and a protective unit, wherein the protective unit is coated on the outside of the signal unit and the optical cable unit, the signal unit comprises a silver-plated copper conductor, an insulation layer, a shielding layer and a jacket layer, the optical cable unit comprises an optical fiber, a buffer tube and a filler; the protective unit comprises an inner jacket, a tensile layer, an anti-corrosion layer and an outer jacket; The surface of the silver-plated copper conductor is coated with a graphene layer; the insulating layer is cross-linked polyethylene; The shielding layer comprises a tinned copper wire braid and a nano-alumina modified aluminum foil wrapping; The sheath layer comprises the following components in parts by mass: 45 parts of EPDM rubber, 30 parts of polyurethane, 6 parts of fumed silica, 4 parts of boron nitride nanosheets, 3 parts of perfluoropolyether oil, 1 part of dipentadienyl vulcanizing agent, and 0.2 parts of accelerator TMTD; The optical fiber in the optical cable unit is embedded in a buffer tube and filled with a filler; the buffer tube is a fluororesin tube, and the filler is hydrogenated nitrile gel; the tensile layer is a mixed braid of aramid fiber and carbon fiber; the material of the inner sheath and the outer sheath is basically the same as the material of the sheath layer. On the basis of the material of the sheath layer, the inner sheath and the outer sheath contain an antistatic agent and a flame retardant. The antistatic agent includes the following components in parts by mass: 1.5 parts of carbon nanotubes (diameter 8-15nm), 0.8 parts of ionic liquid [BMIM]PF, and 0.3 parts of dispersant polyvinyl pyrrolidone; the flame retardant is 1.2 parts of brominated flame retardant; the anti-corrosion layer is 2 parts of tribasic lead sulfate and 4 parts of chlorinated paraffin.

[0049] The method for preparing the corrosion-resistant composite cable comprises the following steps: S1: Composite manufacturing of signal unit, which uses co-extrusion die to extrude conductor insulation layer and shielding layer simultaneously, and then coat with sheath layer; S2: Encapsulating the optical cable unit, performing hydrogenated nitrile gel perfusion; the hydrogenated nitrile gel perfusion includes injection and curing, wherein the injection is performed by hot pressing under a nitrogen environment of 0.05 MPa; the curing includes the first stage, the second stage and the third stage. The curing temperature of the first stage is 80°C and the curing time is 1h; The curing temperature of the second stage is 120°C and the curing time is 2h; The curing temperature of the third stage is 150° C. and the curing time is 1 hour; S3: Co-extrusion vulcanization of protective unit, using twin-screw extrusion; S4: Electron beam post-treatment, the electron beam irradiation dose is 20kGy, to improve the crystallinity of the material.

[0050] Example 2 This embodiment is basically the same as Example 1, except that the sheath layer includes the following components in parts by mass: 40 parts of EPDM rubber, 35 parts of polyurethane, 5 parts of fumed silica, 5 parts of boron nitride nanosheets, 4 parts of perfluoropolyether oil, 1.2 parts of dipentadienyl vulcanizing agent, and 0.4 parts of accelerator TMTD.

[0051] Example 3 This embodiment is basically the same as Example 1, except that the sheath layer includes the following components in parts by mass: 55 parts of EPDM rubber, 28 parts of polyurethane, 8 parts of fumed silica, 4 parts of boron nitride nanosheets, 3 parts of perfluoropolyether oil, 1 part of dipentadienyl vulcanizing agent, and 0.2 parts of accelerator TMTD.

[0052] Example 4 This embodiment is basically the same as Example 1, except that the polyethylene is 105 parts, the antistatic agent includes the following components in parts by mass: 1.6 parts of carbon nanotubes, 0.8 parts of ionic liquid [BMIM]PF, and 0.2 parts of dispersant; and the flame retardant is 1.2 parts of halogen-free flame retardant.

[0053] Example 5 This embodiment is basically the same as embodiment 4, except that the flame retardant is 1.2 parts of a halogen-free flame retardant.

[0054] Example 6 This embodiment is basically the same as embodiment 4, except that the curing includes a first stage, a second stage and a third stage. The curing temperature of the first stage is 75°C and the curing time is 1.5h; The curing temperature of the second stage is 125°C and the curing time is 1.5h; The curing temperature of the third stage is 140° C., and the curing time is 1.5 hours.

[0055] Comparative Example 1 This comparative example is basically the same as Example 1, except that the shielding layer is replaced by an ordinary aluminum-plastic composite tape.

[0056] Comparative Example 2 This comparative example is basically the same as Example 1, except that the inner sheath and the outer sheath are made of polyethylene.

[0057] Comparative Example 3 This comparative example is basically the same as Example 1, except that the hydrogenated nitrile gel is replaced by silicone gel.

[0058] Experimental Case The results of the corrosion-resistant composite cables obtained in Examples 1-6 of the present invention and Comparative Examples 1-3 are shown in Table 1.

[0059] Table 1 Test results of Examples 1-6 and Comparative Examples 1-3

[0060] As can be seen from the above table, the corrosion-resistant composite cable in the embodiment of the present invention exhibits excellent insulation resistance, which indicates that the cable can effectively prevent current leakage, ensure efficient and stable power transmission, and provide reliable power support for electrical equipment; at the same time, under test conditions such as acid and alkali resistance and salt spray resistance, it may exhibit good corrosion resistance, thereby extending the service life of the cable in harsh environments.

[0061] Comparative Example 1 shows that, due to limitations in its material properties, ordinary aluminum-plastic composite tape, used as a shielding layer, cannot effectively shield against electromagnetic interference as effectively as the shielding layer in Example 1. This can affect signal transmission in complex electromagnetic environments, thereby compromising the overall performance of the cable. Furthermore, ordinary aluminum-plastic composite tape may be less resistant to corrosion and susceptible to long-term corrosion, compromising the shielding function and the integrity of the cable.

[0062] Comparative Example 2 shows that polyethylene, used as the inner and outer sheath materials, may have insufficient mechanical properties, such as wear resistance and tear resistance, making it susceptible to damage during installation and use, reducing the cable's protective capabilities. In terms of chemical corrosion resistance, it may not effectively resist the erosion of some chemicals, affecting the cable's service life. Furthermore, polyethylene may have poor flame retardancy, which may not effectively prevent the spread of fire in the event of a fire, posing a safety hazard. These factors collectively contribute to the poor performance of Comparative Example 2.

[0063] Comparative Example 3 shows that silicone gel may not perform as well as hydrogenated nitrile gel in sealing performance, failing to effectively block moisture and impurities from entering the cable interior, thus affecting the cable's electrical performance. Poor compatibility with other materials within the cable can lead to poor interactions between the materials, reducing the cable's overall stability. Furthermore, the shortcomings of conventional gels in special environmental performance, such as high-temperature resistance, make them unsuitable for use in complex environments.

[0064] It should be noted that the present application is not limited to the above-mentioned embodiments. The above-mentioned embodiments are merely examples, and any embodiments having substantially the same structure and effect as the technical concept within the scope of the present application are all included in the technical scope of the present application. In addition, without departing from the scope of the present application, any other embodiments that can be conceived by those skilled in the art and that combine some of the constituent elements in the embodiments are also included in the scope of the present application.

Claims

1. A corrosion-resistant composite cable, characterized in that: It comprises a signal unit (10), an optical cable unit (20) and a protection unit (30), wherein the protection unit (30) is coated on the outside of the signal unit (10) and the optical cable unit (20); The signal unit (10) includes a silver-plated copper conductor (11), an insulating layer (12), a shielding layer (13), and a sheath layer (14); and the protection unit (30) includes an anti-corrosion layer (33).

2. The corrosion-resistant composite cable according to claim 1, characterized in that: The surface of the silver-plated copper conductor (11) is coated with a graphene layer; and / or The insulating layer (12) is cross-linked polyethylene.

3. The corrosion-resistant composite cable according to claim 1, characterized in that: The shielding layer (13) comprises a tinned copper wire braided mesh and a nano-alumina modified aluminum foil wrapping.

4. The corrosion-resistant composite cable according to claim 1, characterized in that: The sheath layer (14) comprises the following components in parts by mass: 40-55 parts of EPDM rubber, 25-35 parts of polyurethane, 5-8 parts of fumed silica, 3-5 parts of boron nitride nanosheets, 2-4 parts of perfluoropolyether oil, 0.8-1.2 parts of vulcanizing agent, and 0.1-0.4 parts of accelerator.

5. The corrosion-resistant composite cable according to claim 1, characterized in that: The optical cable unit (20) comprises an optical fiber (21), a buffer tube (22) and a filler (23); The optical fiber (21) is embedded in a buffer tube (22) and filled with a filler (23); and / or The buffer tube (22) is a fluororesin tube; and / or The filler (23) is hydrogenated nitrile gel.

6. The corrosion-resistant composite cable according to claim 1, characterized in that: The protective unit (30) comprises an inner sheath (31), a tensile layer (32) and an outer sheath (34); The tensile layer (32) is a mixed weave of aramid fibers and carbon fibers; and / or The inner sheath (31) and the outer sheath (34) contain an antistatic agent and a flame retardant, wherein the antistatic agent comprises the following components in parts by mass: 1-2 parts of carbon nanotubes, 0.5-1 parts of ionic liquid [BMIM]PF, and 0.1-0.5 parts of a dispersant; and / or the flame retardant is a brominated flame retardant or a halogen-free flame retardant.

7. The corrosion-resistant composite cable according to claim 1, characterized in that: The anti-corrosion layer (33) comprises 1-2 parts of tribasic lead sulfate and 3-5 parts of chlorinated paraffin.

8. A method for preparing the corrosion-resistant composite cable according to any one of claims 1 to 7, characterized in that: The following steps are involved: S1: Composite manufacturing of signal unit, which uses co-extrusion die to extrude conductor insulation layer and shielding layer simultaneously, and then coat with sheath layer; S2: Optical cable unit packaging, hydrogenated nitrile gel perfusion; S3: Co-extrusion vulcanization of protective unit, using twin-screw extrusion; S4: Electron beam post-processing to improve material crystallinity.

9. The method for preparing the corrosion-resistant composite cable according to claim 8, characterized in that: The hydrogenated nitrile gel perfusion includes glue injection and curing, wherein the glue injection is performed by hot pressing and packaging under a nitrogen environment of 0.05 MPa; and / or The curing includes a first stage, a second stage and a third stage, The curing temperature of the first stage is 75-85°C and the curing time is 0.5-1.5h; and / or The curing temperature of the second stage is 110-130° C. and the curing time is 1.5-2.5 hours; and / or The curing temperature of the third stage is 140-160° C., and the curing time is 0.5-1.5 hours.

10. The method for preparing the corrosion-resistant composite cable according to claim 8, characterized in that: The irradiation dose of the electron beam is 15-20 kGy.

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