Cold-resistant electric wire and cable and preparation process thereof

Abstract

The invention discloses a cold-resistant electric wire and cable and a preparation process thereof, the cold-resistant electric wire and cable comprises a central conductor, and an insulating layer, a shape memory alloy layer and a sheath layer which sequentially wrap the central conductor, the central conductor is formed by twisting a plurality of strands of guide cores, and the guide cores are tinned copper guide cores; the insulating layer comprises a cold-resistant base layer and an aerogel composite layer, the cold-resistant base layer is prepared by mixing and co-extruding matrix resin, a plasticizer, a lubricant, a stabilizer and a silicon dioxide nucleating agent according to the proportion of 42: 7: 2: 0.5: 0.3, and the cold-resistant base layer is wrapped with the aerogel composite layer; the shape memory alloy layer is of a net-shaped structure woven by nickel-titanium alloy wires and covers the aerogel composite layer; the sheath layer is a cold-resistant chloroprene rubber sheath or a polyurethane sheath. According to the cable, by optimizing the structural design and material selection, it is ensured that the wire cable can still keep excellent physical and electrical performance in an extremely low temperature environment.

Description

Technical Field

[0001] The present invention relates to the field of electric wires and cables, and in particular to a cold-resistant electric wire and cable and a preparation process thereof. Background Art

[0002] The booming development of industrial automation, urban power grid upgrades, renewable energy development, smart city construction, and telecommunications has placed higher demands on the performance of power transmission and communication equipment. This is especially true in applications in extremely cold and freezing environments. Traditional cables are susceptible to material brittleness and aging, which can affect their proper operation and safety. Therefore, ensuring the stability and reliability of power and communication equipment in extremely low temperatures has become a significant challenge.

[0003] The flexibility and aging resistance of existing cold-resistant wires and cables in low-temperature environments are still limited. Especially in extremely low-temperature environments (such as -50°C and below), the insulation layer of the cable is prone to brittleness, resulting in electrical performance failure. In addition, although the cable sheath layer can provide a certain degree of protection, its cold resistance and resistance to water vapor permeability are insufficient, resulting in water vapor condensation affecting the insulation performance, and ultimately causing premature aging or damage to the cable. Therefore, how to improve the performance of cables in extremely low-temperature environments, especially insulation performance, brittleness resistance and service life extension, has become a key issue that needs to be urgently addressed in the field of cable technology. Summary of the Invention

[0004] The purpose of the present invention is to provide a cold-resistant wire and cable and its preparation process, which ensures that the excellent physical and electrical properties can be maintained in extremely low temperature environments by optimizing the structural design and material selection, thereby significantly improving the cold resistance and reliability of the cable.

[0005] To achieve the above-mentioned objectives, the present invention provides the following technical solutions: a cold-resistant wire and cable, comprising a central conductor and an insulating layer, a shape memory alloy layer and a sheath layer sequentially wrapped around the central conductor, wherein: the central conductor is formed by twisting multiple conductor cores, and the conductor core is a tinned copper conductor core; the insulating layer comprises a cold-resistant base layer and an aerogel composite layer, wherein the cold-resistant base layer is made by co-extrusion of a matrix resin, a plasticizer, a lubricant, a stabilizer and a silica nucleating agent in a ratio of 42:7:2:0.5:0.3, and the aerogel composite layer is wrapped around the cold-resistant base layer; the shape memory alloy layer is a mesh structure woven from Ni-Ti (nickel-titanium) alloy wires and covered on the outside of the aerogel composite layer; the sheath layer is a cold-resistant chloroprene rubber sheath or a polyurethane sheath.

[0006] Preferably, the base resin is a cold-resistant thermoplastic elastomer, the plasticizer is dioctyl adipate, the lubricant is zinc stearate, and the stabilizer is a calcium-zinc composite stabilizer. The cold-resistant thermoplastic elastomer provides basic insulation performance and maintains flexibility at low temperatures. The plasticizer can lower the glass transition temperature and improve flexibility. The plasticizer lowers the glass transition temperature of TPE to below -45°C, while zinc stearate further promotes chain segment movement at low temperatures by reducing molecular chain entanglement, so that the material still maintains an elongation at break of ≥200% at -50°C. The long hydrophobic chain of zinc stearate and the hydrophobic layer of the calcium-zinc stabilizer work together to prevent water molecules from penetrating into the interior of the material, avoiding the degradation of insulation performance due to water vapor condensation at low temperatures.

[0007] Preferably, the aerogel composite layer is formed by compounding aerogel and phase change material by vacuum impregnation, and the outer side of the aerogel composite layer is wrapped with a microporous breathable membrane (pore size 0.1-1 μm).

[0008] Preferably, the phase change material is paraffin or fatty acid material, and the aerogel is silica aerogel (porosity ≥ 95%, particle size 100-500 μm, thermal conductivity ≤ 0.02 W / (m·K)). The aerogel needs to be vacuum dried before processing to remove moisture in the aerogel pores to avoid bubbles when the PCM (phase change material) is loaded.

[0009] Preferably, the vacuum impregnation method is to immerse the aerogel in molten PCM, with a vacuum degree of -0.1 MPa, for 30 minutes to ensure an adsorption rate of ≥90%. The aerogel PCM particles treated by the vacuum impregnation method are mixed with a binder and pressed into a base material to be wrapped around the cold-resistant base layer.

[0010] Preferably, a flexible heating wire is further provided in the shape memory alloy layer, and the flexible heating wire is cross-woven and embedded in the gaps of the Ni-Ti (nickel titanium) alloy wire mesh.

[0011] Preferably, an aerogel polyurethane composite coating (thickness 50-100 μm) is provided inside the sheath layer, and a super hydrophobic coating (fluorocarbon resin + nano titanium dioxide composite coating) is coated outside the sheath layer.

[0012] The present invention also proposes a preparation process for the above-mentioned cold-resistant wire and cable, comprising the following steps:

[0013] S1: The copper rod is drawn into a single-wire conductor with a diameter of 0.1 to 0.3 mm through a multi-pass wire drawing machine. Tin plating is completed simultaneously during the drawing process, and the thickness of the tin layer is ≥ 2 μm;

[0014] S2: Using concentric layer stranding technology, multiple strands of tinned copper cores are twisted into conductors with a twist pitch of 15 to 20 times the core diameter to form a flexible conductor structure.

[0015] S3: Weigh cold-resistant thermoplastic elastomer, dioctyl adipate, zinc stearate, calcium zinc composite stabilizer, and silica nucleating agent in a mass ratio of 42:7:2:0.5:0.3 and premix them in a high-speed mixer for 5 minutes;

[0016] S4: Add the mixed material into a twin-screw extruder at a temperature of 160-180°C, and wrap the conductor with a cold-resistant base layer through a co-extrusion die with a thickness of 0.3-0.5 mm;

[0017] S5: Dry the silica aerogel in a vacuum drying oven for 12 hours to remove moisture from the pores;

[0018] S6: Immerse the dried aerogel in molten paraffin or fatty acid phase change material and keep it at -0.1MPa vacuum for 30 minutes. The adsorption rate is ≥90%;

[0019] S7: mixing the impregnated aerogel PCM particles with a polyurethane binder, molding them into an aerogel composite layer with a thickness of 0.5 to 0.8 mm by compression molding, and wrapping it with a microporous breathable membrane;

[0020] S8: Use Ni-Ti shape memory alloy wire with a diameter of 0.05-0.1mm, use the insulation layer as the core shaft, weave Ni-Ti alloy wire mesh directly on its outer surface, cross-weave flexible heating wires and embed them into the gaps of Ni-Ti alloy wire mesh. The spacing between the heating wires is 5-10mm to form a continuous and seamless heating memory alloy composite layer.

[0021] S9: aerogel powder (particle size 10-50 μm) is mixed with polyurethane resin (mass ratio 3:7), and a composite coating with a thickness of 50-100 μm is formed on the inner surface of the jacket layer by a spraying process; a dispersion of fluorocarbon resin and nano-titanium dioxide (mass ratio 9:1) is sprayed on the outer surface of the jacket layer, and a super-hydrophobic coating (contact angle ≥150°) is formed after curing;

[0022] S10: Wrap the sheath layer around the heat-resistant memory alloy composite layer, and complete the preparation of the cold-resistant wire and cable.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] By optimizing the structural design and material selection, the cable of the present invention ensures that it can maintain excellent physical and electrical properties in extremely low temperature environments. In particular, it ensures that the cable does not become brittle or break under low temperature conditions, and can maintain high flexibility and insulation performance, significantly improving the cold resistance and reliability of the cable. Specific technical advantages include the following:

[0025] 1. This invention uses a cold-resistant thermoplastic elastomer as the base insulation layer. By combining additives such as plasticizers and lubricants, the material's glass transition temperature is significantly lowered, enabling the cable to maintain high flexibility and elongation at break even in low-temperature environments. Even in temperatures of -50°C or below, the cable maintains excellent physical properties, avoiding the failures of traditional cables caused by brittle cracking or aging.

[0026] 2. This invention incorporates an aerogel composite layer within the insulation layer. Aerogel, with its high porosity, low thermal conductivity, and excellent thermal insulation properties, effectively isolates the cable from external cold, maintains a stable temperature within the cable, and enhances the cable's insulation performance. Furthermore, the aerogel composite layer is wrapped with a microporous breathable membrane, further enhancing the cable's stability in low-temperature environments. The synergistic effect of aerogel and PCM ensures that the cable maintains a stable internal temperature for extended periods in low-temperature environments, minimizing performance degradation caused by temperature fluctuations.

[0027] 3. By introducing a shape memory alloy layer, the present invention achieves intelligent protection and adaptive adjustment of cables in extreme environments. The Ni-Ti shape memory alloy mesh works in conjunction with a flexible heating wire. When the ambient temperature or the cable surface temperature drops below freezing, the heating wire is energized and heated, raising the temperature of the shape memory alloy layer (SMA layer) to the austenite transition temperature, triggering radial contraction of the alloy mesh. This deformation force actively squeezes the sheath layer, removing surface ice within 5 minutes, and improving de-icing efficiency by more than 50% compared to traditional heating methods. In addition, the SMA mesh is embedded in the cable structure, providing radial restraint at room temperature, inhibiting interlayer delamination between the sheath layer and the insulation layer (peel strength ≥ 8N / mm), and enhancing the cable's impact resistance, making it capable of withstanding ice and snow pressure. The shape memory alloy layer works in conjunction with the cold-resistant TPE insulation layer and the aerogel / PCM composite insulation layer to form a three-level protection system of "active protection, passive insulation, and intelligent adjustment" to adapt to low-temperature environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a comparison chart of the cold resistance and anti-icing ability of the comparative example and Examples 1, 2, 3, and 4 in a specific embodiment of the present invention. DETAILED DESCRIPTION

[0029] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0030] In the description of the present invention, it should be noted that the terms "vertical", "up", "down", "horizontal", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as limiting the present invention.

[0031] In the description of the present invention, it should also be noted that, unless otherwise expressly specified or limited, the terms "disposed," "installed," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to mechanical connections or electrical connections; they may refer to direct connections or indirect connections through an intermediate medium; and they may refer to internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0032] The present invention provides a technical solution: a cold-resistant electric wire and cable, comprising a central conductor and an insulating layer, a shape memory alloy layer and a sheath layer which are sequentially wrapped around the central conductor.

[0033] In this embodiment, the central conductor is formed by twisting multiple conductor cores, and the conductor cores are tinned copper conductor cores.

[0034] In this embodiment, the insulation layer includes a cold-resistant base layer and an aerogel composite layer, wherein the cold-resistant base layer is made by co-extrusion of a matrix resin, a plasticizer, a lubricant, a stabilizer, and a silica nucleating agent in a ratio of 42:7:2:0.5:0.3, and the aerogel composite layer is wrapped around the cold-resistant base layer.

[0035] In this embodiment, the shape memory alloy layer is a mesh structure woven from Ni-Ti (nickel-titanium) alloy wires and covers the aerogel composite layer.

[0036] In this embodiment, the sheath layer is a cold-resistant chloroprene rubber sheath or a polyurethane sheath.

[0037] Example 1: A process for preparing cold-resistant wires and cables, comprising the following steps:

[0038] S1: The copper rod is drawn into a single-wire conductor with a diameter of 0.1 to 0.3 mm through a multi-pass wire drawing machine. Tin plating is completed simultaneously during the drawing process, and the thickness of the tin layer is ≥ 2 μm;

[0039] S2: Using concentric layer stranding technology, multiple strands of tinned copper cores are twisted into conductors with a twist pitch of 15 to 20 times the core diameter to form a flexible conductor structure.

[0040] S3: Weigh cold-resistant thermoplastic elastomer, dioctyl adipate, zinc stearate, calcium zinc composite stabilizer, and silica nucleating agent in a mass ratio of 42:7:2:0.5:0.3 and premix them in a high-speed mixer for 5 minutes;

[0041] S4: Add the mixed material into a twin-screw extruder at a temperature of 160-180°C, and wrap the conductor with a cold-resistant base layer through a co-extrusion die with a thickness of 0.3-0.5 mm;

[0042] S5: Wrap the sheath layer around the cold-resistant base layer, and complete the preparation of the cold-resistant wire and cable.

[0043] In Example 1, a cold-resistant thermoplastic elastomer (TPE) matrix is ​​used in combination with dioctyl adipate (DOA) plasticizer to ensure that the cable remains flexible (elongation at break ≥ 200%) at a low temperature of -60°C, thus avoiding brittle cracking. The concentric layer stranding process and 15-20 times stranding pitch design ensure that the conductor bending radius is ≤ 8 times the outer diameter of the cable, adapting to frequent bending requirements in extreme environments. The cold-resistant base layer has a thickness of 0.3-0.5mm, providing basic insulation and mechanical protection, and is suitable for conventional cold-resistant scenarios (such as power transmission in high-latitude areas).

[0044] Example 2: A process for preparing cold-resistant wires and cables, comprising the following steps:

[0045] S1: The copper rod is drawn into a single-wire conductor with a diameter of 0.1 to 0.3 mm through a multi-pass wire drawing machine. Tin plating is completed simultaneously during the drawing process, and the thickness of the tin layer is ≥ 2 μm;

[0046] S2: Using concentric layer stranding technology, multiple strands of tinned copper cores are twisted into conductors with a twist pitch of 15 to 20 times the core diameter to form a flexible conductor structure.

[0047] S3: Weigh cold-resistant thermoplastic elastomer, dioctyl adipate, zinc stearate, calcium zinc composite stabilizer, and silica nucleating agent in a mass ratio of 42:7:2:0.5:0.3 and premix them in a high-speed mixer for 5 minutes;

[0048] S4: Add the mixed material into a twin-screw extruder at a temperature of 160-180°C, and wrap the conductor with a cold-resistant base layer through a co-extrusion die with a thickness of 0.3-0.5 mm;

[0049] S5: Dry the silica aerogel in a vacuum drying oven for 12 hours to remove moisture from the pores;

[0050] S6: Immerse the dried aerogel in molten paraffin or fatty acid phase change material and keep it at -0.1MPa vacuum for 30 minutes. The adsorption rate is ≥90%;

[0051] S7: mixing the impregnated aerogel PCM particles with a polyurethane binder, molding them into an aerogel composite layer with a thickness of 0.5 to 0.8 mm by compression molding, and wrapping it with a microporous breathable membrane;

[0052] S8: Wrap the sheath layer outside the aerogel composite layer and complete the preparation of the cold-resistant wire and cable.

[0053] In Example 2, the silica aerogel is impregnated with a paraffin / fatty acid phase change material (PCM) to form an aerogel composite layer, and the thermal conductivity is reduced to ≤0.04W / (m·K), an 80% reduction compared to Example 1. The latent heat storage properties of PCM (phase change enthalpy ≥150J / g) can buffer temperature fluctuations and delay thermal stress damage to the cable during cycling from -60°C to room temperature. The aerogel composite layer has a thickness of 0.5 to 0.8mm, which enables the cable to maintain the thermal stability of the conductor and insulation layer at ultra-low temperatures of -80°C, making it suitable for scenarios such as polar scientific research and spacecraft cables.

[0054] Example 3: A process for preparing cold-resistant wires and cables, comprising the following steps:

[0055] S1: The copper rod is drawn into a single-wire conductor with a diameter of 0.1 to 0.3 mm through a multi-pass wire drawing machine. Tin plating is completed simultaneously during the drawing process, and the thickness of the tin layer is ≥ 2 μm;

[0056] S2: Using concentric layer stranding technology, multiple strands of tinned copper cores are twisted into conductors with a twist pitch of 15 to 20 times the core diameter to form a flexible conductor structure.

[0057] S3: Weigh cold-resistant thermoplastic elastomer, dioctyl adipate, zinc stearate, calcium zinc composite stabilizer, and silica nucleating agent in a mass ratio of 42:7:2:0.5:0.3 and premix them in a high-speed mixer for 5 minutes;

[0058] S4: Add the mixed material into a twin-screw extruder at a temperature of 160-180°C, and wrap the conductor with a cold-resistant base layer through a co-extrusion die with a thickness of 0.3-0.5 mm;

[0059] S5: Dry the silica aerogel in a vacuum drying oven for 12 hours to remove moisture from the pores;

[0060] S6: Immerse the dried aerogel in molten paraffin or fatty acid phase change material and keep it at -0.1MPa vacuum for 30 minutes. The adsorption rate is ≥90%;

[0061] S7: mixing the impregnated aerogel PCM particles with a polyurethane binder, molding them into an aerogel composite layer with a thickness of 0.5 to 0.8 mm by compression molding, and wrapping it with a microporous breathable membrane;

[0062] S8: Use Ni-Ti shape memory alloy wire with a diameter of 0.05-0.1mm, use the insulation layer as the core shaft, weave Ni-Ti alloy wire mesh directly on its outer surface, cross-weave flexible heating wires and embed them into the gaps of Ni-Ti alloy wire mesh. The spacing between the heating wires is 5-10mm to form a continuous and seamless heating memory alloy composite layer.

[0063] S9: Wrap the sheath layer around the heat-resistant memory alloy composite layer, and complete the preparation of the cold-resistant wire and cable.

[0064] In Example 3, a Ni-Ti shape memory alloy mesh (diameter 0.05-0.1mm) and a flexible heating wire (spacing 5-10mm) are embedded to form a heating memory alloy composite layer. When powered on for heating, the heating wire heats the SMA layer to the austenite phase transition temperature (Af = 40-60°C), triggering shape recovery and squeezing the sheath layer, actively shedding the surface ice layer (de-icing time ≤ 5 minutes). The SMA wire mesh provides radial restraint, enhances the impact resistance of the cable (such as resisting deformation caused by ice and snow pressure), and inhibits interlayer delamination between the sheath layer and the insulation layer. Combining the passive insulation of the aerogel composite layer with the active heating of the SMA layer, rapid melting of the ice layer and minimization of heat loss at low temperatures of -60°C are achieved, making it suitable for wind farms and transmission cables in high-altitude and cold mountainous areas.

[0065] Example 4: A process for preparing cold-resistant wires and cables, comprising the following steps:

[0066] S1: The copper rod is drawn into a single-wire conductor with a diameter of 0.1 to 0.3 mm through a multi-pass wire drawing machine. Tin plating is completed simultaneously during the drawing process, and the thickness of the tin layer is ≥ 2 μm;

[0067] S2: Using concentric layer stranding technology, multiple strands of tinned copper cores are twisted into conductors with a twist pitch of 15 to 20 times the core diameter to form a flexible conductor structure.

[0068] S3: Weigh cold-resistant thermoplastic elastomer, dioctyl adipate, zinc stearate, calcium zinc composite stabilizer, and silica nucleating agent in a mass ratio of 42:7:2:0.5:0.3 and premix them in a high-speed mixer for 5 minutes;

[0069] S4: Add the mixed material into a twin-screw extruder at a temperature of 160-180°C, and wrap the conductor with a cold-resistant base layer through a co-extrusion die with a thickness of 0.3-0.5 mm;

[0070] S5: Dry the silica aerogel in a vacuum drying oven for 12 hours to remove moisture from the pores;

[0071] S6: Immerse the dried aerogel in molten paraffin or fatty acid phase change material and keep it at -0.1MPa vacuum for 30 minutes. The adsorption rate is ≥90%;

[0072] S7: mixing the impregnated aerogel PCM particles with a polyurethane binder, molding them into an aerogel composite layer with a thickness of 0.5 to 0.8 mm by compression molding, and wrapping it with a microporous breathable membrane;

[0073] S8: Use Ni-Ti shape memory alloy wire with a diameter of 0.05-0.1mm, use the insulation layer as the core shaft, weave Ni-Ti alloy wire mesh directly on its outer surface, cross-weave flexible heating wires and embed them into the gaps of Ni-Ti alloy wire mesh. The spacing between the heating wires is 5-10mm to form a continuous and seamless heating memory alloy composite layer.

[0074] S9: aerogel powder (particle size 10-50 μm) is mixed with polyurethane resin (mass ratio 3:7), and a composite coating with a thickness of 50-100 μm is formed on the inner surface of the jacket layer by a spraying process; a dispersion of fluorocarbon resin and nano-titanium dioxide (mass ratio 9:1) is sprayed on the outer surface of the jacket layer, and a super-hydrophobic coating (contact angle ≥150°) is formed after curing;

[0075] S10: Wrap the sheath layer around the heat-resistant memory alloy composite layer, and complete the preparation of the cold-resistant wire and cable.

[0076] In Example 4, the outer surface of the jacket layer is sprayed with a fluorocarbon resin + nano-titanium dioxide super-hydrophobic coating (contact angle ≥ 150°, rolling angle ≤ 10°), so that water droplets form spheres on the surface and roll down quickly, reducing the adhesion of the ice layer (ice adhesion after freezing ≤ 5kPa). The inner surface of the jacket layer is sprayed with an aerogel / polyurethane composite coating (thickness 50-100μm), further reducing the thermal conductivity of the jacket layer to ≤ 0.2W / (m·K), reducing heat loss during heating of the SMA layer, and improving the anti-icing efficiency by more than 30%. Example 4 constructs a three-level protection system of "super-hydrophobic outer surface (anti-ice adhesion) + aerogel inner coating (thermal insulation) + SMA heating layer (active deicing)", achieving zero ice accumulation in the cycle from -60°C to room temperature, and is suitable for extreme ice and snow environments (such as Arctic power transmission and aviation cables).

[0077] Comparative Example 1: Conventional cold-resistant wire and cable, using conductor + ordinary cold-resistant TPE insulation layer + ordinary sheath layer, has qualified flexibility at -20℃, brittle cracking at -40℃, no active anti-icing function, ice layer adhesion of about 20kPa, and thermal conductivity of about 0.35W / (m·K).

[0078] This embodiment also provides a performance comparison table of the above embodiments and comparative examples:

[0079]

[0080]

[0081] Combined with the above table and Figure 1To explain:

[0082] Cold resistance: Example 1 achieves -60°C flexibility through the cold-resistant TPE material, Example 2 extends it to ultra-low temperature stability of -80°C through the aerogel composite layer, and Examples 3 and 4 further enhance deformation resistance due to the SMA layer constraint.

[0083] Anti-icing capability: The comparative example and Example 1 have no active anti-icing function, and the ice layer adhesion is relatively high; Example 2 reduces the ice layer adhesion by using aerogel insulation; Examples 3 and 4 achieve efficient anti-icing through SMA active heating or superhydrophobic coating.

[0084] Thermal insulation: The aerogel composite layer (Example 2) and the aerogel inner coating (Examples 3 and 4) significantly reduce thermal conductivity and reduce heat loss.

[0085] SMA heating function: Only embodiments 3 and 4 have an SMA heating layer to achieve active deicing.

[0086] Superhydrophobicity: Only Example 4 has a superhydrophobic coating, which further reduces the adhesion of the ice layer.

[0087] Applicable environment: The comparative example is applicable to conventional low temperature, Example 1 is applicable to general cold resistance, Example 2 is applicable to polar ultra-low temperature, Example 3 is applicable to dynamic deicing in high-altitude mountainous areas, and Example 4 is applicable to extreme ice and snow environments.

[0088] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A cold-resistant wire and cable comprising a central conductor and an insulation layer, a shape memory alloy layer, and a sheath layer sequentially wrapped around the central conductor, characterized in that: The center conductor is made of multiple strands of conductor core, and the conductor core is tinned copper conductor core; The insulation layer includes a cold-resistant base layer and an aerogel composite layer, wherein the cold-resistant base layer is made by co-extrusion of a matrix resin, a plasticizer, a lubricant, a stabilizer, and a silica nucleating agent in a ratio of 42:7:2:0.5:0.3, and the aerogel composite layer is wrapped around the cold-resistant base layer; The shape memory alloy layer is a mesh structure woven from nickel-titanium alloy wires and covers the aerogel composite layer; The sheath layer is a cold-resistant neoprene sheath or polyurethane sheath.

2. The cold-resistant wire and cable according to claim 1, characterized in that: The matrix resin is a cold-resistant thermoplastic elastomer, the plasticizer is dioctyl adipate, the lubricant is zinc stearate, and the stabilizer is a calcium-zinc composite stabilizer.

3. The cold-resistant wire and cable according to claim 1, characterized in that: The aerogel composite layer is compounded by aerogel and phase change material by using a vacuum impregnation method and is wrapped around the cold-resistant base layer. The outer side of the aerogel composite layer is wrapped with a microporous breathable film.

4. The cold-resistant wire and cable according to claim 1, characterized in that: The phase change material is paraffin or fatty acid material, and the aerogel is silicon dioxide aerogel.

5. The cold-resistant wire and cable according to claim 1, characterized in that: The vacuum impregnation method is to immerse the aerogel in the molten phase change material, with a vacuum degree of -0.1MPa, for 30 minutes, and mix the treated aerogel phase change material particles with a binder, and press them into a base material to wrap the cold-resistant base layer.

6. The cold-resistant wire and cable according to claim 1, characterized in that: The shape memory alloy layer is further provided with a flexible heating wire, which is cross-woven and embedded in the gaps of the nickel-titanium alloy wire mesh.

7. The cold-resistant wire and cable according to claim 1, characterized in that: An aerogel polyurethane composite coating is provided inside the sheath layer, and a super hydrophobic coating is coated outside the sheath layer.

8. The cold-resistant wire and cable according to claim 1, characterized in that: The super-hydrophobic coating is formed by mixing fluorocarbon resin and nano-titanium dioxide dispersion in a mass ratio of 3:

7.

9. A process for preparing a cold-resistant electric wire and cable according to any one of claims 1 to 8, characterized in that: Including steps: S1: The copper rod is drawn into a single-wire conductor with a diameter of 0.1 to 0.3 mm through a multi-pass wire drawing machine. Tin plating is completed simultaneously during the drawing process, and the thickness of the tin layer is ≥ 2 μm; S2: Multiple strands of tinned copper conductors are twisted into a conductor with a twist pitch of 15 to 20 times the conductor diameter to form a flexible conductor structure. S3: Weigh cold-resistant thermoplastic elastomer, dioctyl adipate, zinc stearate, calcium zinc composite stabilizer, and silica nucleating agent in a mass ratio of 42:7:2:0.5:0.3 and premix them in a high-speed mixer for 5 minutes; S4: Add the mixed material into a twin-screw extruder at a temperature of 160-180°C, and wrap the conductor with a cold-resistant base layer through a co-extrusion die with a thickness of 0.3-0.5 mm; S5: Dry the silica aerogel in a vacuum drying oven for 12 hours to remove moisture from the pores; S6: Immerse the dried aerogel in molten paraffin or fatty acid phase change material and keep it at -0.1MPa vacuum for 30 minutes. The adsorption rate is ≥90%; S7: mixing the impregnated aerogel phase change material particles with a polyurethane binder, molding them into an aerogel composite layer with a thickness of 0.5 to 0.8 mm by molding, and wrapping it with a microporous breathable membrane; S8: Use nickel-titanium alloy wire with a diameter of 0.05-0.1mm, use the insulation layer as the core shaft, weave nickel-titanium alloy wire mesh directly on its outer surface, cross-weave flexible heating wires and embed them into the gaps of the nickel-titanium alloy wire mesh. The spacing between the heating wires is 5-10mm to form a continuous and seamless heating alloy composite layer. S9: mixing the aerogel powder with the polyurethane resin, and forming a composite coating having a thickness of 50 to 100 μm on the inner surface of the sheath layer through a spraying process; Spraying fluorocarbon resin and nano-titanium dioxide dispersion on the outer surface of the sheath layer to form a super-hydrophobic coating after curing; S10: Wrap the sheath layer around the heat-resistant memory alloy composite layer, and complete the preparation of the cold-resistant wire and cable.

Images