Forming device and forming method of high-temperature-resistant low-temperature-resistant high-toughness cable

Abstract

The invention discloses a forming device and a forming method of a high-temperature-resistant low-temperature-resistant high-toughness cable. According to the invention, based on a double-substrate synergistic system of hydrogenated nitrile rubber and polyether type thermoplastic polyurethane, and in combination with a dynamic vulcanization crosslinking technology, the cable keeps excellent flexibility and tear resistance in a wide temperature range of-60 DEG C to 125 DEG C. A three-dimensional reinforced network of nano silicon dioxide and carbon nanotubes is directionally dispersed in a matrix, and mechanical support of aramid short fibers is matched, so that the cable is endowed with bending fatigue resistance, the durability of the drag chain cable in a high-frequency torsion scene of an oil platform exceeds 30 million cycles is realized, and the service life of the drag chain cable is prolonged. The problem of breakage caused by low-temperature embrittlement and high-temperature softening of a traditional cable is fundamentally solved, the synergistic effect of the perfluoropolyether surface modifier and the composite anti-aging system enables the cable to form a stable protective layer in strong acid, strong alkali, salt mist and oil stain environments, and chemical corrosion and ultraviolet irradiation are effectively resisted.

Description

Technical Field

[0001] The invention belongs to the technical field of oil platform cables, and in particular relates to a forming device and a forming method for a high-temperature-resistant, low-temperature-resistant and high-toughness cable. Background Art

[0002] Oil rig cables are specialized cables designed specifically for the harshest offshore and onshore drilling environments. They offer exceptional resistance to oil, acids, alkalis, weathering, and mechanical properties. These cables typically utilize a high-quality copper or aluminum conductor, covered with a heat-resistant and abrasion-resistant insulation layer. Common materials include cross-linked polyethylene (XLPE) or ethylene propylene rubber (EPR), ensuring stable electrical performance in high temperatures, high pressures, and corrosive environments. The cable's structural design fully addresses the unique requirements of drilling platforms and typically incorporates reinforcement layers such as steel wire armor or aramid fiber to enhance tensile and compressive resistance to withstand the intense vibration and mechanical shock experienced during platform operations. Furthermore, oil rig cables exhibit excellent flexibility and torsional resistance to withstand the frequent bending and rotation of drilling equipment. Their jackets are typically constructed of highly weather-resistant composites such as neoprene or polyurethane to resist UV rays, seawater, oil, and chemical corrosion, ensuring long-term, safe, and reliable operation in these harsh environments. They are essential components for power transmission, signal control, and data communications on oil rigs.

[0003] However, due to the single base material and uneven dispersion of fillers, traditional cables are prone to brittle fracture or softening deformation in extreme high and low temperature environments, and the number of bending resistance is far lower than the actual demand; the protection system lacks chemical stability and anti-aging coordinated design, resulting in poor corrosion resistance and short service life; the rough cross-linking process causes internal stress concentration, and structural failure is prone to occur after long-term use, which makes it difficult to meet the requirements of oil platform drag chain systems for material weather resistance, fatigue resistance and long-term reliability. Summary of the Invention

[0004] The object of the present invention is to provide a molding device and a molding method for a high-temperature-resistant and low-temperature-resistant high-toughness cable in order to solve the above-mentioned problems.

[0005] The technical solution adopted by the present invention is as follows: a molding method of a high-temperature-resistant and low-temperature-resistant high-toughness cable, the molding method comprising the following steps: S1: Weigh the following raw materials: 70 parts by weight of hydrogenated nitrile rubber, 30 parts by weight of polyether thermoplastic polyurethane, 15 parts by weight of surface-modified nano-silica, 5 parts by weight of aramid staple fibers, 3 parts by weight of functionalized carbon nanotubes, 8 parts by weight of dioctyl adipate, 2 parts by weight of perfluoropolyether, 1.5 parts by weight of hindered amine light stabilizer, 2 parts by weight of phenolic and thioester composite antioxidant, 1.2 parts by weight of peroxide crosslinking agent, and 0.5 parts by weight of silane coupling agent KH-550; dry the hydrogenated nitrile rubber and polyether thermoplastic polyurethane separately, add them into an internal mixer in proportion, and premix them at a set temperature to form a preliminary blending system; S2: Add surface-modified nano-silica, functionalized carbon nanotubes and aramid staple fibers into the internal mixer and disperse them into the matrix through high-speed shear force to ensure that the fillers are evenly distributed and form an interpenetrating network structure.

[0006] S3: Add dioctyl adipate plasticizer, composite antioxidant and hindered amine light stabilizer into the internal mixer in stages, control the temperature to avoid volatilization of the plasticizer, and continue mixing until the system is completely plasticized.

[0007] S4: Peroxide crosslinking agent and silane coupling agent are injected during the mixing process, and high-density crosslinking bonds are formed between the base material and the filler through dynamic vulcanization technology to improve the material strength and temperature resistance.

[0008] S5: The mixed rubber material is transferred to a twin-screw extruder, and the screw speed and temperature parameters are adjusted to continuously extrude the cable sheath or insulation layer, and then shaped through a mold.

[0009] S6: Place the extruded cable in a vulcanization box and use a step-by-step temperature increase method to complete the initial cross-linking reaction to ensure that the material surface is cured and the internal structure is stabilized.

[0010] S7: Increase the vulcanization temperature for secondary cross-linking and extend the vulcanization time to optimize the molecular chain arrangement density so that the cable as a whole can meet the requirements of high and low temperature resistance and fatigue resistance.

[0011] S8: The vulcanized cable is subjected to surface matte treatment, and after cooling, it is cut into standard lengths. The bending resistance, tensile strength and chemical corrosion resistance are tested in sequence to ensure that it meets the standards for extreme environmental applications.

[0012] In a preferred embodiment, in step S1, the thermoplastic polyester elastomer is one of polybutylene terephthalate-polytetramethylene ether block copolymer, polyethylene terephthalate-polyether block copolymer, or polybutylene adipate-polytetramethylene ether block copolymer; The polyether thermoplastic polyurethane is one of polytetramethylene ether thermoplastic polyurethane, polypropylene glycol ether thermoplastic polyurethane or polycaprolactone ether thermoplastic polyurethane; The surface-modified nano-silica is nano-silica that has been surface-treated with a silane coupling agent KH-570 or a titanate coupling agent NDZ-101; The aramid staple fiber is one of para-aramid fiber, meta-aramid fiber or copolymerized aramid fiber; The functionalized carbon nanotubes are one of carboxyl-modified multi-walled carbon nanotubes, hydroxyl-modified multi-walled carbon nanotubes, and amino-modified multi-walled carbon nanotubes; The composite antioxidant is a mixture of pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] and dilauryl thiodipropionate in a mass ratio of 1:1; The perfluoropolyether is a linear perfluoropolyether oil or a branched perfluoropolyether oil with a molecular weight of 2000-5000; The hindered amine light stabilizer is one of the polymeric hindered amine light stabilizer HALS-944 or the low molecular weight hindered amine light stabilizer HALS-622; Hydrogenated nitrile rubber (HNBR) and polyether thermoplastic polyurethane (TPU) were placed in a vacuum drying oven at 80°C for 4 hours to remove moisture. The two materials were then placed in an internal mixer at a weight ratio of 70:30. The mixer was set at 140°C and a rotor speed of 40 rpm for 20 minutes to form a preliminary blend. This stage softens the materials and promotes initial entanglement between molecular segments, laying the foundation for subsequent filler dispersion.

[0013] In a preferred embodiment, in step S2, nanosilica modified with a silane coupling agent KH-570, para-aramid staple fibers, and carboxylated multi-walled carbon nanotubes are added to an internal mixer. The rotor speed is increased to 60 rpm, the temperature is maintained at 140°C, and mixing is continued for 30 minutes. High-speed shear forces are used to evenly disperse the nanofiller and align the aramid fibers, forming a three-dimensional reinforced network.

[0014] In a preferred embodiment, in step S3, dioctyl adipate plasticizer, an antioxidant comprising pentaerythritol tetra-β-3,5-di-tert-butyl-4-hydroxyphenylpropionate and dilauryl thiodipropionate, and a polymeric hindered amine light stabilizer HALS-944 are sequentially added to an internal mixer in three batches. The mixing temperature is controlled below 130°C, and the total mixing time is 40 minutes, with a five-minute interval between each batch to ensure full integration of the plasticizer and the matrix.

[0015] In a preferred embodiment, in step S4, a peroxide crosslinking agent DCP and a silane coupling agent KH-550 are injected into the rubber compound, the internal mixer temperature is raised to 160 degrees Celsius, the rotor speed is adjusted to 30 rpm, and the dynamic vulcanization reaction is continued for 25 minutes. The crosslinking agent initiates chemical bonding, forming a high-density crosslinked network, thereby improving the material's temperature resistance and tensile strength.

[0016] In a preferred embodiment, in step S5, the rubber material is transferred to a twin-screw extruder, and the temperatures of zones 1 to 4 are set to 150°C, 160°C, 155°C, and 145°C, respectively. The screw speed is set to 25 rpm, and the extrusion pressure is set to 12 MPa. After melt extrusion, the rubber material is formed into a cable sheath through an annular die, resulting in a smooth, defect-free surface.

[0017] In a preferred embodiment, in step S6, the extruded cable is placed in a vulcanization chamber and heated from room temperature to 160 degrees Celsius at a rate of 5 degrees Celsius per minute and maintained at this temperature for 10 minutes. This stage allows for rapid crosslinking and curing of the surface layer, preliminarily stabilizing the cable structure.

[0018] In a preferred embodiment, in step S7, the vulcanization temperature is raised to 180 degrees Celsius and the temperature is kept constant for 4 hours to promote deep cross-linking of the molecular chains and a cross-linking density of 1.2×10^4 cross-linking points per cubic centimeter, thereby completely eliminating internal stress and ensuring stable performance of the cable at 125 degrees Celsius.

[0019] In a preferred embodiment, in step S8, the vulcanized cable is naturally cooled at room temperature for 24 hours, followed by a surface atomization treatment using a fumed silica matting agent to reduce the surface gloss to less than 10 gloss units. After being cut to standard lengths, the cable is sequentially tested for bending endurance, tensile strength, and chemical corrosion resistance. These tests are conducted in accordance with international standards ISO 6722, ASTM D412, and ASTM D471, ensuring that the cable withstands at least 30 million bending cycles, has a tensile strength of at least 25 MPa, and exhibits no cracking after immersion in a 10% sulfuric acid solution for 168 hours.

[0020] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are: 1. This invention utilizes a dual-matrix synergistic system of hydrogenated nitrile rubber and polyether thermoplastic polyurethane, combined with dynamic vulcanization crosslinking technology, to ensure the cable maintains excellent flexibility and tear resistance over a wide temperature range of -60°C to 125°C. A three-dimensional reinforced network of nanosilica and carbon nanotubes, directionally dispersed within the matrix and mechanically supported by aramid staple fibers, imparts bending fatigue resistance to the cable. This ensures the cable's durability exceeds 30 million cycles under high-frequency torsion conditions found on oil platforms, fundamentally addressing the breakage issues associated with traditional cables, which often arise from low-temperature embrittlement and high-temperature softening.

[0021] 2. In the present invention, the synergistic effect of the perfluoropolyether surface modifier and the composite anti-aging system enables the cable to form a stable protective layer in strong acid, strong alkali, salt spray and oily environments, effectively resisting chemical corrosion and ultraviolet radiation. The molecular chain cross-linking density is optimized through a step-vulcanization process to eliminate internal stress concentration, ensuring that the cable maintains structural integrity under long-term high and low temperature cycles, mechanical vibrations and complex media corrosion. The surface atomization treatment technology further reduces gloss, avoids reflective interference in the working environment, and enhances wear resistance. The cable prepared by this method has adaptability to extreme environments, long-term reliability and safety, and fully meets the stringent requirements of the oil drilling platform drag chain system for material weather resistance, aging resistance and mechanical stability. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the process principle of the present invention. DETAILED DESCRIPTION

[0023] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0024] Example: Reference Figure 1 A method for forming a high-temperature-resistant and low-temperature-resistant high-toughness cable, the method comprising the following steps: S1: Weigh the following raw materials: 70 parts by weight of hydrogenated nitrile rubber, 30 parts by weight of polyether thermoplastic polyurethane, 15 parts by weight of surface-modified nano-silica, 5 parts by weight of aramid staple fibers, 3 parts by weight of functionalized carbon nanotubes, 8 parts by weight of dioctyl adipate, 2 parts by weight of perfluoropolyether, 1.5 parts by weight of hindered amine light stabilizer, 2 parts by weight of phenolic and thioester composite antioxidant, 1.2 parts by weight of peroxide crosslinking agent, and 0.5 parts by weight of silane coupling agent KH-550; dry the hydrogenated nitrile rubber and polyether thermoplastic polyurethane separately, add them into an internal mixer in proportion, and premix them at a set temperature to form a preliminary blending system; S2: Add surface-modified nano-silica, functionalized carbon nanotubes and aramid staple fibers into the internal mixer and disperse them into the matrix through high-speed shear force to ensure that the fillers are evenly distributed and form an interpenetrating network structure.

[0025] S3: Add dioctyl adipate plasticizer, composite antioxidant and hindered amine light stabilizer into the internal mixer in stages, control the temperature to avoid volatilization of the plasticizer, and continue mixing until the system is completely plasticized.

[0026] S4: Peroxide crosslinking agent and silane coupling agent are injected during the mixing process, and high-density crosslinking bonds are formed between the base material and the filler through dynamic vulcanization technology to improve the material strength and temperature resistance.

[0027] S5: The mixed rubber material is transferred to a twin-screw extruder, and the screw speed and temperature parameters are adjusted to continuously extrude the cable sheath or insulation layer, and then shaped through a mold.

[0028] S6: Place the extruded cable in a vulcanization box and use a step-by-step temperature increase method to complete the initial cross-linking reaction to ensure that the material surface is cured and the internal structure is stabilized.

[0029] S7: Increase the vulcanization temperature for secondary cross-linking and extend the vulcanization time to optimize the molecular chain arrangement density so that the cable as a whole can meet the requirements of high and low temperature resistance and fatigue resistance.

[0030] S8: The vulcanized cable is subjected to surface matte treatment, and after cooling, it is cut into standard lengths. The bending resistance, tensile strength and chemical corrosion resistance are tested in sequence to ensure that it meets the standards for extreme environmental applications.

[0031] In step S1, the thermoplastic polyester elastomer is one of polybutylene terephthalate-polytetramethylene furan block copolymer, polyethylene terephthalate-polyether block copolymer, or polybutylene adipate-polytetramethylene furan block copolymer; the polyether-type thermoplastic polyurethane is one of polytetramethylene furan ether-type thermoplastic polyurethane, polypropylene glycol ether-type thermoplastic polyurethane, or polycaprolactone ether-type thermoplastic polyurethane; Surface modified nano-silica is nano-silica that has been surface treated with silane coupling agent KH-570 or titanate coupling agent NDZ-101; The aramid staple fiber is one of para-aramid fiber, meta-aramid fiber or copolymerized aramid fiber; The functionalized carbon nanotubes are one of carboxyl-modified multi-walled carbon nanotubes, hydroxyl-modified multi-walled carbon nanotubes, and amino-modified multi-walled carbon nanotubes; The composite antioxidant is a mixture of pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] and dilauryl thiodipropionate in a mass ratio of 1:1; The perfluoropolyether is a linear perfluoropolyether oil or a branched perfluoropolyether oil having a molecular weight of 2000-5000; The hindered amine light stabilizer is one of the polymeric hindered amine light stabilizer HALS-944 or the low molecular weight hindered amine light stabilizer HALS-622; Hydrogenated nitrile rubber (HNBR) and polyether thermoplastic polyurethane (TPU) were placed in a vacuum drying oven at 80°C for 4 hours to remove moisture. The two materials were then placed in an internal mixer at a weight ratio of 70:30. The mixer was set at 140°C and a rotor speed of 40 rpm for 20 minutes to form a preliminary blend. This stage softens the materials and promotes initial entanglement between molecular segments, laying the foundation for subsequent filler dispersion.

[0032] In step S2, nanosilica modified with the silane coupling agent KH-570, para-aramid staple fibers, and carboxylated multi-walled carbon nanotubes are added to an internal mixer. The rotor speed is increased to 60 rpm, and the temperature is maintained at 140°C. Mixing is continued for 30 minutes. High shear forces are applied to evenly disperse the nanofiller and align the aramid fibers, forming a three-dimensional reinforced network.

[0033] In step S3, dioctyl adipate plasticizer, an antioxidant (pentaerythritol tetra-β-3,5-di-tert-butyl-4-hydroxyphenylpropionate and dilauryl thiodipropionate), and HALS-944 (a polymeric hindered amine light stabilizer) were added sequentially to an internal mixer in three batches. Each batch was added five minutes apart, and the mixing temperature was maintained below 130°C for a total of 40 minutes to ensure full integration of the plasticizer and the matrix.

[0034] In step S4, the peroxide crosslinker DCP and the silane coupling agent KH-550 are injected into the rubber compound. The internal mixer temperature is raised to 160 degrees Celsius, the rotor speed is adjusted to 30 rpm, and the dynamic vulcanization reaction is continued for 25 minutes. The crosslinker initiates chemical bonding, forming a high-density crosslinked network, which improves the material's temperature resistance and tensile strength.

[0035] In step S5, the rubber material is transferred to a twin-screw extruder. The temperatures in zones 1 through 4 are set to 150°C, 160°C, 155°C, and 145°C, respectively. The screw speed is set to 25 rpm, and the extrusion pressure is set to 12 MPa. After melt extrusion, the rubber material is formed into a cable sheath through an annular die, resulting in a smooth, defect-free surface.

[0036] In step S6, the extruded cable is placed in a vulcanization chamber and heated from room temperature to 160 degrees Celsius at a rate of 5 degrees Celsius per minute, and maintained at this temperature for 10 minutes. This stage allows for rapid crosslinking and curing of the surface layer, initially stabilizing the cable structure.

[0037] In step S7, the vulcanization temperature is raised to 180 degrees Celsius and kept at a constant temperature for 4 hours to promote deep cross-linking of the molecular chains and a cross-linking density of 1.2×10^4 cross-linking points per cubic centimeter, completely eliminating internal stress and ensuring stable performance of the cable at 125 degrees Celsius.

[0038] In step S8, the vulcanized cable is naturally cooled at room temperature for 24 hours. The surface is then atomized using a fumed silica matting agent to reduce the surface gloss to less than 10 gloss units. After being cut to standard lengths, the cable is then tested for bending endurance, tensile strength, and chemical corrosion resistance. These tests adhere to international standards ISO 6722, ASTM D412, and ASTM D471, ensuring the cable withstands at least 30 million bending cycles, has a tensile strength of at least 25 MPa, and exhibits no cracking after immersion in a 10% sulfuric acid solution for 168 hours.

[0039] Test example: Use traditional oil platform drag chain cable (the matrix is ​​single nitrile rubber, the filler is ordinary calcium carbonate, and there is no dynamic cross-linking process).

[0040] Test items: temperature resistance, bending resistance, tensile strength, chemical corrosion resistance, aging resistance and surface characteristics.

[0041] Description of the test method for high temperature and low temperature resistant and high toughness cables 1. Temperature resistance test Test standard: GB / T 2951.12 Test method: Low temperature test: Place the cable sample in a -60℃ low temperature box for constant temperature treatment for 24 hours. After taking it out, immediately perform a 180° bending test to observe whether the surface is cracked or brittle.

[0042] High temperature test: Place the sample in a 125℃ high temperature box for 48 hours to detect whether the sample softens or deforms, and test the tensile strength retention rate.

[0043] Evaluation indicators: No cracks at low temperature, no deformation at high temperature and tensile strength retention rate ≥ 95% are qualified.

[0044] 2. Bending resistance test Test standard: ISO 6722 Test method: Fix the cable on the drag chain test machine, set the bending radius to 7 times the cable outer diameter, and perform one-way or two-way bending cycles at a speed of 30 times per minute.

[0045] The test is continued until the cable sheath cracks or the conductor breaks, and the total number of bends is recorded.

[0046] Evaluation index: Bending resistance ≥ 30 million times is qualified.

[0047] 3. Tensile strength test Test standard: ASTM D412 Test method: The cable sheath material is made into a standard dumbbell-shaped test piece and stretched using a universal material testing machine at a tensile rate of 500 mm / min.

[0048] Record the maximum tensile force when the specimen breaks and calculate the tensile strength (unit: MPa).

[0049] Evaluation index: tensile strength ≥25MPa is qualified.

[0050] 4. Chemical corrosion resistance test Test standard: ASTM D471 Test method: Immerse the cable specimens in a 10% sulfuric acid solution and diesel fuel, respectively, at a temperature of 23±2°C for 168 hours. Remove the specimens, clean the surface, and observe for any swelling, cracks, or shedding. Test the tensile strength retention after immersion.

[0051] Evaluation indicators: No visible damage and tensile strength retention rate ≥ 90% are qualified.

[0052] 5. Anti-aging performance test Test standard: ASTM G154 Test method: Place the sample in a UV aging box to simulate sunlight ultraviolet radiation (wavelength 340nm, irradiation intensity 0.76W / m 2 ), the cycle is 8 hours of illumination / 4 hours of condensation, with a total duration of 2000 hours.

[0053] Test whether the surface is powdered or cracked after aging, and detect changes in tensile strength.

[0054] Evaluation indicators: Surface no powdering, no cracks and tensile strength retention rate ≥ 85% are qualified.

[0055] 6. Surface properties test Test standard: ASTM D523 Test method: Use a gloss meter to measure the surface gloss of the cable sheath at a 60° angle of incidence and record the gloss units (GU). Compare the gloss data before and after matte treatment to evaluate the surface matte effect.

[0056] Evaluation index: Surface gloss ≤10GU is qualified.

[0057] The test results are shown in the table below: This test example compares the key performance indicators of a conventional cable and the cable of the present invention to demonstrate that the molding method of this embodiment has the following significant advantages: Extreme temperature adaptability: The test group maintained flexibility at -60°C, showed no softening or deformation at 125°C, and retained over 95% of its tensile strength, completely resolving the defects of traditional cables such as embrittlement at low temperatures and loss of strength at high temperatures.

[0058] Long-term durability: The bending resistance is increased to more than 30 million times, and the tensile strength is increased by 55%, meeting the high-frequency torsion requirements of the oil platform drag chain system.

[0059] Environmental tolerance: Under the long-term effects of strong acid, diesel and ultraviolet rays, the test group showed no corrosion and swelling, no aging and powdering, and the strength retention rate was higher than 90%, which was significantly better than the control group.

[0060] Safety and functionality: Matte surface treatment reduces gloss to 8GU, avoiding reflections and enhancing wear resistance.

[0061] The experimental data fully verified the technical advancement and reliability of the method of the present invention in extreme industrial scenarios.

[0062] From the above, we can see that the present invention's dual-matrix synergistic system of hydrogenated nitrile rubber and polyether thermoplastic polyurethane, combined with dynamic vulcanization crosslinking technology, enables the cable to maintain excellent flexibility and tear resistance over a wide temperature range of -60°C to 125°C. A three-dimensional reinforced network of nanosilica and carbon nanotubes, directionally dispersed in the matrix and mechanically supported by aramid staple fibers, imparts bending fatigue resistance to the cable, enabling the drag chain cable to withstand over 30 million cycles in high-frequency torsion scenarios on oil platforms. This fundamentally addresses the breakage issues associated with traditional cables, which often arise from low-temperature embrittlement and high-temperature softening.

[0063] In the present invention, the synergistic effect of the perfluoropolyether surface modifier and the composite anti-aging system enables the cable to form a stable protective layer in strong acid, strong alkali, salt spray and oily environments, effectively resisting chemical corrosion and ultraviolet radiation. The molecular chain cross-linking density is optimized through a step-vulcanization process to eliminate internal stress concentration, ensuring that the cable maintains structural integrity under long-term high and low temperature cycles, mechanical vibrations and complex media erosion. The surface atomization treatment technology further reduces gloss, avoids reflective interference in the working environment, and enhances wear resistance. The cable prepared by this method has adaptability to extreme environments, long-term reliability and safety, and fully meets the stringent requirements of the oil drilling platform drag chain system for material weather resistance, aging resistance and mechanical stability.

[0064] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply the existence of any such actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article, or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or elements inherent to such process, method, article, or device. In the absence of further limitations, an element defined by the phrase "comprising a ..." does not exclude the presence of other identical elements in the process, method, article, or device comprising the element.

[0065] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A method for forming a high-temperature and low-temperature resistant high-toughness cable, characterized in that: The molding method comprises the following steps: S1: Weigh the following raw materials: 70 parts by weight of hydrogenated nitrile rubber, 30 parts by weight of polyether thermoplastic polyurethane, 15 parts by weight of surface-modified nano-silica, 5 parts by weight of aramid staple fibers, 3 parts by weight of functionalized carbon nanotubes, 8 parts by weight of dioctyl adipate, 2 parts by weight of perfluoropolyether, 1.5 parts by weight of hindered amine light stabilizer, 2 parts by weight of phenolic and thioester composite antioxidant, 1.2 parts by weight of peroxide crosslinking agent, and 0.5 parts by weight of silane coupling agent KH-550; dry the hydrogenated nitrile rubber and polyether thermoplastic polyurethane separately, add them into an internal mixer in proportion, and premix them at a set temperature to form a preliminary blending system; S2: Add surface-modified nano-silica, functionalized carbon nanotubes, and aramid staple fibers into an internal mixer and disperse them into the matrix through high-speed shear force to ensure uniform distribution of the fillers and form an interpenetrating network structure; S3: Add dioctyl adipate plasticizer, composite antioxidant and hindered amine light stabilizer into the internal mixer in stages, control the temperature to prevent the plasticizer from volatilizing, and continue mixing until the system is completely plasticized; S4: Inject peroxide crosslinking agent and silane coupling agent during the mixing process, and use dynamic vulcanization technology to form high-density crosslinking bonds between the base material and the filler, thereby improving the material strength and temperature resistance; S5: Transfer the mixed rubber material to a twin-screw extruder, adjust the screw speed and temperature parameters, continuously extrude it into a cable sheath or insulation layer, and shape it through a mold; S6: Place the extruded cable in a vulcanization chamber and use a step-by-step temperature increase method to complete the initial cross-linking reaction to ensure that the material surface is cured and the internal structure is stabilized; S7: Increase the vulcanization temperature for secondary cross-linking and extend the vulcanization time to optimize the molecular chain arrangement density so that the cable as a whole meets the requirements of high and low temperature resistance and fatigue resistance; S8: The vulcanized cable is subjected to surface matte treatment, and after cooling, it is cut into standard lengths. The bending resistance, tensile strength and chemical corrosion resistance are tested in sequence to ensure that it meets the standards for extreme environmental applications.

2. The method for forming a high-temperature and low-temperature resistant high-toughness cable according to claim 1, characterized in that: In step S1, the thermoplastic polyester elastomer is one of polybutylene terephthalate-polytetramethylene furan block copolymer, polyethylene terephthalate-polyether block copolymer or polybutylene adipate-polytetramethylene furan block copolymer; The polyether thermoplastic polyurethane is one of polytetramethylene ether thermoplastic polyurethane, polypropylene glycol ether thermoplastic polyurethane or polycaprolactone ether thermoplastic polyurethane; The surface-modified nano-silica is nano-silica that has been surface-treated with a silane coupling agent KH-570 or a titanate coupling agent NDZ-101; The aramid staple fiber is one of para-aramid fiber, meta-aramid fiber or copolymerized aramid fiber; The functionalized carbon nanotubes are one of carboxyl-modified multi-walled carbon nanotubes, hydroxyl-modified multi-walled carbon nanotubes, and amino-modified multi-walled carbon nanotubes; The composite antioxidant is a mixture of pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] and dilauryl thiodipropionate in a mass ratio of 1:1; The perfluoropolyether is a linear perfluoropolyether oil or a branched perfluoropolyether oil with a molecular weight of 2000-5000; The hindered amine light stabilizer is one of the polymeric hindered amine light stabilizer HALS-944 or the low molecular weight hindered amine light stabilizer HALS-622; Hydrogenated nitrile rubber (HNBR) and polyether thermoplastic polyurethane (TPU) were placed in a vacuum drying oven and dried at 80°C for 4 hours to remove moisture. The two materials were then put into an internal mixer in a mass ratio of 70:

30. The mixer temperature was set at 140°C and the rotor speed was set at 40 rpm. The mixture was premixed for 20 minutes to form a preliminary blending system. During this stage, thermal energy was used to soften the material and promote the initial entanglement between molecular chain segments, laying the foundation for subsequent filler dispersion.

3. The method for forming a high-temperature and low-temperature resistant high-toughness cable according to claim 1, characterized in that: In step S2, nano-silica modified with silane coupling agent KH-570, para-aramid short fibers, and carboxylated multi-walled carbon nanotubes are added to an internal mixer; the rotor speed is increased to 60 rpm, the temperature is maintained at 140 degrees Celsius, and mixing is carried out for 30 minutes. High-speed shear force is used to evenly disperse the nano-filler and align the aramid fibers to form a three-dimensional reinforced network.

4. The method for forming a high-temperature and low-temperature resistant high-toughness cable according to claim 1, characterized in that: In step S3, dioctyl adipate plasticizer, an antioxidant compounded of pentaerythritol tetra-β-3,5-di-tert-butyl-4-hydroxyphenylpropionate and dilauryl thiodipropionate, and a polymeric hindered amine light stabilizer HALS-944 are sequentially added to the internal mixer in three batches; each batch is added at an interval of 5 minutes, the mixing temperature is controlled below 130 degrees Celsius, and the total mixing time is 40 minutes to ensure that the plasticizer is fully integrated with the matrix.

5. The method for forming a high-temperature and low-temperature resistant high-toughness cable according to claim 1, characterized in that: In step S4, a peroxide crosslinking agent DCP and a silane coupling agent KH-550 are injected into the rubber material, the temperature of the internal mixer is raised to 160 degrees Celsius, the rotor speed is adjusted to 30 revolutions per minute, and the dynamic vulcanization reaction is continued for 25 minutes; the crosslinking agent initiates chemical bonding to form a high-density crosslinked network, thereby improving the temperature resistance and tensile strength of the material.

6. The method for forming a high-temperature and low-temperature resistant high-toughness cable according to claim 1, characterized in that: In step S5, the rubber material is transferred to a twin-screw extruder, and the temperatures of zones 1 to 4 are set to 150 degrees Celsius, 160 degrees Celsius, 155 degrees Celsius, and 145 degrees Celsius, respectively, the screw speed is 25 rpm, and the extrusion pressure is 12 MPa; after the rubber material is melted and extruded, it is formed into a cable sheath through an annular die with a smooth and defect-free surface.

7. The method for forming a high-temperature and low-temperature resistant high-toughness cable according to claim 1, characterized in that: In step S6, the extruded cable is placed in a vulcanization box, heated from room temperature to 160 degrees Celsius at a rate of 5 degrees Celsius per minute, and kept at a constant temperature for 10 minutes; during this stage, the surface layer is rapidly cross-linked and cured, and the cable structure is initially stabilized.

8. The method for forming a high-temperature and low-temperature resistant high-toughness cable according to claim 1, characterized in that: In step S7, the vulcanization temperature is raised to 180 degrees Celsius and the temperature is kept constant for 4 hours to promote deep cross-linking of the molecular chains, with a cross-linking density of 1.2×10^4 cross-linking points per cubic centimeter, completely eliminating internal stress and ensuring stable performance of the cable at 125 degrees Celsius.

9. The method for forming a high-temperature and low-temperature resistant high-toughness cable according to claim 1, characterized in that: In step S8, the vulcanized cable is naturally cooled in a room temperature environment for 24 hours, and then surface atomization treatment is performed using a fumed silica matting agent to reduce the surface gloss to less than 10 gloss units. After cutting into standard lengths, the cable is sequentially subjected to a bending resistance test, a tensile strength test, and a chemical corrosion resistance test. The test standards are respectively ISO 6722, ASTM D412, and ASTM D471, ensuring that the cable has a bending resistance of not less than 30 million times, a tensile strength of not less than 25 MPa, and no cracking after being immersed in a 10% by mass sulfuric acid solution for 168 hours.

10. A molding device for high-temperature and low-temperature resistant high-toughness cables, characterized by: The device uses the molding method of high-temperature-resistant and low-temperature-resistant high-toughness cable as described in any one of claims 1 to 9 to mold the cable.

Images