High strength abrasion resistant tpu jacketed cable and process for making same

Abstract

The application discloses a kind of high-strength wear-resistant TPU sheath cable and manufacturing process thereof.The high-strength wear-resistant TPU sheath cable includes cable conductor, insulating layer, shielding layer and sheath layer covered in turn from inside to outside, the sheath layer is prepared using the following components by weight percentage: TPU resin 60-75%, reinforcing fiber 10-20%, wear-resistant filler 5-15%, antioxidant 0.2-0.5%, lubricant 0.5-1% and flame retardant 5-10%.The sheath layer of the cable has high strength, wear resistance, weather resistance and flame retardant performance, which can effectively protect the cable in various harsh working conditions.

Description

Technical Field

[0001] This invention relates to the field of wire and cable manufacturing technology, and in particular to a high-strength, wear-resistant TPU-sheathed cable and its manufacturing process. Background Technology

[0002] With the rapid development of industrial automation, rail transportation, and other fields, the requirements for cable performance are becoming increasingly stringent, especially in outdoor environments. Cables must possess high strength, excellent wear resistance, and weather resistance to ensure stable operation in various harsh conditions. The outermost layer of the cable is the sheath, which protects the innermost cable conductor from external factors and is a key factor in ensuring cable lifespan and safety. Cables using traditional PVC or rubber sheaths have the following drawbacks: 1) Insufficient tensile strength and abrasion resistance make the sheath layer prone to tearing or wear in applications where cables are frequently dragged and rubbed. 2) When used in the field, factors such as sunlight, temperature, humidity, and rain can cause the performance of the sheath layer to deteriorate, resulting in poor weather resistance; 3) Poor flame retardant properties are not conducive to reducing fire risk, resulting in significant safety hazards in scenarios such as rail transit and high-rise buildings.

[0003] How to solve the above-mentioned defects has become a technical problem that urgently needs to be solved in the current field. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the purpose of this invention is to provide a high-strength wear-resistant TPU sheathed cable and its manufacturing process. The sheath layer has high strength, wear resistance, weather resistance and flame retardant properties, thereby effectively ensuring the long-term stable use of the cable in various harsh working conditions.

[0005] The high-strength, wear-resistant TPU-sheathed cable of this invention is achieved through the following technical solution: A high-strength, abrasion-resistant TPU-sheathed cable includes, from the inside out, a cable conductor, an insulation layer, a shielding layer, and a sheath layer, wherein the sheath layer is prepared from the following components by weight percentage: The composition consists of 60-75% TPU resin, 10-20% reinforcing fiber, 5-15% wear-resistant filler, 0.2-0.5% antioxidant, 0.5-1% lubricant, and 5-10% flame retardant.

[0006] Furthermore, the TPU resin is thermoplastic polyurethane, with a Shore A hardness of 85-95 and a molecular weight of 80,000-120,000.

[0007] Furthermore, the reinforcing fiber is one or more of glass fiber, carbon fiber, or aramid fiber; the reinforcing fiber is pretreated by plasma and cut to 0.2-0.8 mm.

[0008] Furthermore, the wear-resistant filler is one or more of silicon carbide, alumina, or silicon dioxide.

[0009] Furthermore, the flame retardant comprises microencapsulated red phosphorus and magnesium hydroxide, and the mass ratio of microencapsulated red phosphorus to magnesium hydroxide is (0.5~0.7):1; wherein the microencapsulated red phosphorus has a particle size of 5~10μm and is coated with a silane coupling agent on its surface.

[0010] Furthermore, the lubricant contains silicone and zinc stearate, and the mass ratio of silicone to zinc stearate is (1-1.5):1.

[0011] Furthermore, the antioxidant comprises hindered phenolic antioxidant 1010 and phosphite antioxidant 168, and the mass ratio of hindered phenolic antioxidant 1010 to phosphite antioxidant 168 is 1:(1-2).

[0012] The manufacturing process of this invention is achieved using the following technical solution: A manufacturing process for a high-strength, abrasion-resistant TPU-sheathed cable as described above includes the following steps: S1. Prepare the cable conductor; S2. Prepare single-core or multi-core insulated conductors. A single-core insulated conductor is obtained by covering the outside of a single cable conductor with an insulation layer, and a multi-core insulated conductor is obtained by stranding multiple single-core insulated conductors. S3. A braided shielding layer is wrapped around the outside of a single-core or multi-core insulated conductor to obtain a cable core; S4. Prepare the TPU sheath layer and wrap it around the outside of the cable core.

[0013] Further, step S4 includes: S4-1. A staged feeding method is adopted. In the first stage, TPU resin and 30%~50% flame retardant are added to the internal mixer and heated and mixed at a temperature of 160-170℃ and 40~50 rpm to melt the TPU resin into a uniform matrix. In the second stage, the remaining flame retardant and other components are added and mixed at a temperature of 170~180℃ and 50~60 rpm. S4-2. The material discharged from the internal mixer enters the granulator for pelletizing. The material discharged from the granulator is then vacuum dried to obtain TPU granular material. S4-3. TPU granules are added to an extruder to prepare a TPU sheath layer. After the TPU sheath layer is discharged from the extruder, it undergoes vacuum sizing, adsorption bonding, water cooling and shaping, and traction winding to cover the outside of the cable core.

[0014] Furthermore, the extruder includes a feeding zone, a melting zone, a mixing zone, and a die head arranged sequentially. The temperature of the feeding zone is controlled at 170~175℃, the temperature of the melting zone is controlled at 180~185℃, the temperature of the mixing zone is controlled at 185~190℃, and the temperature of the die head is controlled at 190~195℃.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention relates to a high-strength wear-resistant TPU sheathed cable and its manufacturing process, wherein the sheath layer has high strength, wear resistance, weather resistance and flame retardant properties, thereby effectively ensuring the long-term stable use of the cable in various harsh working conditions. Attached Figure Description

[0016] Figure 1 This is a flowchart illustrating the manufacturing process of the high-strength, wear-resistant TPU-sheathed cable of the present invention. Detailed Implementation

[0017] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0018] This invention provides a high-strength, abrasion-resistant TPU-sheathed cable and its manufacturing process. The high-strength, abrasion-resistant TPU-sheathed cable includes, from the inside out, a cable conductor, an insulation layer, a shielding layer, and a sheath layer. The sheath layer is prepared using the following components in weight percentages: The composition consists of 60-75% TPU resin, 10-20% reinforcing fiber, 5-15% wear-resistant filler, 0.2-0.5% antioxidant, 0.5-1% lubricant, and 5-10% flame retardant.

[0019] In the high-strength wear-resistant TPU sheathed cable of this embodiment, the TPU resin is thermoplastic polyurethane with a Shore A hardness of 85-95 and a molecular weight of 80,000-120,000. This TPU resin material has excellent elasticity, wear resistance and weather resistance.

[0020] In the high-strength, wear-resistant TPU-sheathed cable of this embodiment, the reinforcing fiber is one or more of glass fiber, carbon fiber, or aramid fiber; the reinforcing fiber is pretreated by plasma and cut to a length of 0.2-0.8 mm. The reinforcing fiber is used to improve the tensile strength and tear resistance of the sheath layer. The fiber length is moderate, preventing low reinforcement efficiency due to insufficient stress transfer caused by excessive length, and avoiding agglomeration during processing due to excessive length, which could lead to internal defects in the sheath layer. After plasma treatment, the strong bond between the fiber and the TPU matrix can inhibit microcrack propagation, and the enhanced interfacial bonding can improve the performance retention rate of the TPU sheath layer in humid and hot environments, thus improving weather resistance.

[0021] In the high-strength, abrasion-resistant TPU-sheathed cable of this embodiment, the abrasion-resistant filler is one or more of silicon carbide, alumina, or silica. Adding abrasion-resistant filler can further enhance abrasion resistance.

[0022] In the high-strength, wear-resistant TPU sheathed cable of this embodiment, the flame retardant comprises microencapsulated red phosphorus and magnesium hydroxide, with a mass ratio of microencapsulated red phosphorus to magnesium hydroxide of (0.5~0.7):1. The microencapsulated red phosphorus has a particle size of 5~10 μm and is coated with a silane coupling agent. When the particle size is <5 μm, it is prone to agglomeration, leading to uneven dispersion; when the particle size is >10 μm, the phosphorus release rate is slow due to insufficient specific surface area. Therefore, a particle size of 5~10 μm is used to balance uniform dispersion and release rate, thereby improving flame retardant performance. Traditional flame retardants tend to cause a significant decrease in the tensile strength of the sheath layer after addition. However, by coating red phosphorus with a silane coupling agent, its compatibility with the TPU matrix is ​​improved, effectively reducing the decrease in tensile strength caused by the addition of flame retardants, thus achieving a balance between tensile strength and flame retardant performance. The synergistic effect of microencapsulated red phosphorus and magnesium hydroxide increases the oxygen index. The microencapsulation structure inhibits the oxidation of red phosphorus to produce toxic gases such as PH3, making it more environmentally friendly. The microencapsulation structure can also delay the hydrolysis of red phosphorus, improve the performance retention rate in humid and hot environments, and enhance weather resistance.

[0023] In the high-strength, wear-resistant TPU sheathed cable of this embodiment, the lubricant comprises silicone and zinc stearate, with a mass ratio of silicone to zinc stearate of (1-1.5):1. This lubricant improves processing performance by reducing friction between the melt and processing equipment, as well as reducing friction between molecular chains. This improves melt flowability, reduces the extrusion pressure of the TPU sheath, and eliminates sharkskin defects on the output surface.

[0024] In the high-strength, abrasion-resistant TPU-sheathed cable of this embodiment, the antioxidant comprises hindered phenolic antioxidant 1010 and phosphite antioxidant 168, and the mass ratio of hindered phenolic antioxidant 1010 to phosphite antioxidant 168 is 1:(1-2). The antioxidant effectively enhances thermal and oxygen stability and improves weather resistance.

[0025] The optimal ratio of each component in the sheath layer of the high-strength, abrasion-resistant TPU-sheathed cable in this embodiment can be referenced from the following scheme: Option 1: 70% TPU resin, 12% aramid fiber, 9% silicon carbide, 0.3% antioxidant (1010 / 168=1:2), 0.7% lubricant (0.4% silicone + 0.3% zinc stearate), 8% flame retardant (3% microencapsulated red phosphorus + 5% magnesium hydroxide). Option 2: 65% TPU resin, 12% aramid fiber, 6% carbon fiber, 6% silicon carbide, 0.4% antioxidant, 0.6% lubricant, and 10% flame retardant.

[0026] The manufacturing process of the high-strength, wear-resistant TPU sheathed cable in this embodiment includes the following steps S1 to S4: S1. Prepare the cable conductor; S2. Prepare single-core or multi-core insulated conductors. A single-core insulated conductor is obtained by covering the outside of a single cable conductor with an insulation layer, and a multi-core insulated conductor is obtained by stranding multiple single-core insulated conductors. S3. A braided shielding layer is wrapped around the outside of a single-core or multi-core insulated conductor to obtain a cable core; S4. Prepare the TPU sheath layer and wrap it around the outside of the cable core.

[0027] Step S4 includes: S4-1. Using a staged feeding method, in the first stage, TPU resin and 30%~50% flame retardant are added to a mixer (e.g., a Banbury type mixer) and heated and mixed at a temperature of 160-170℃ and 40~50 rpm to melt the TPU resin into a uniform matrix. In the second stage, the remaining flame retardant and other components are added and mixed at a temperature of 170~180℃ and 50~60 rpm. S4-2. The material discharged from the internal mixer is fed into a granulator (e.g., a twin-screw granulator) for pelletizing. The material discharged from the granulator is then vacuum dried to obtain TPU granular material. S4-3. TPU granules are added to an extruder (e.g., a two-stage co-rotating twin-screw extruder) to prepare a TPU sheath layer. After the TPU sheath layer is discharged from the extruder, it undergoes vacuum sizing adsorption, water cooling shaping, and traction winding to cover the outside of the cable core.

[0028] In step S4-1 above, the purpose of staged feeding is that if all components are added at once, the large amount of magnesium hydroxide added at once will adsorb too much melt, causing a sharp increase in the system viscosity. The uncontrollable melt viscosity results in a higher required torque, which in turn leads to a significant increase in the fiber breakage rate. Therefore, only TPU resin and part of the flame retardant are added in the first stage, and the remaining materials are added in the second stage. Combined with a lubricant, the fluid performance is further improved, thereby achieving a moderate viscosity, reducing the required torque, lowering the fiber breakage rate, and improving the sheath strength. Furthermore, staged feeding helps disperse the flame retardant and improves the flame retardant stability.

[0029] Preferably, the extruder includes a feeding zone, a melting zone, a mixing zone, and a die arranged sequentially. The temperature of the feeding zone is controlled at 170~175℃, the temperature of the melting zone is controlled at 180~185℃, the temperature of the mixing zone is controlled at 185~190℃, and the temperature of the die is controlled at 190~195℃. Controlling the feeding zone temperature to 170~175℃, for example, 175℃, helps prevent premature melting that could cause feeding fluctuations. Controlling the melting zone temperature to 180~185℃ is because the peak melting temperature of TPU is approximately 180℃; a certain degree of overheating, for example, to 183℃, allows for rapid melting and improves flow properties. Controlling the mixing zone temperature to 185~190℃, for example, to 188℃, further improves melt flowability, reduces viscosity, and achieves uniform dispersion of the components. Controlling the die temperature to 190~195℃ further reduces flow properties and viscosity, thereby significantly reducing extrusion swell. Based on the above temperature gradient control, a high-efficiency, low-consumption, and high-precision preparation process for the sheath layer is achieved.

[0030] In summary, the high-strength wear-resistant TPU sheathed cable and its manufacturing process provided by the embodiments of the present invention achieve a sheath layer that combines high strength, wear resistance, weather resistance and flame retardancy, thereby effectively ensuring the long-term stable use of the cable in various harsh working conditions.

[0031] The above embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial changes and substitutions made by those skilled in the art based on the present invention shall fall within the scope of protection claimed by the present invention.

Claims

1. A high-strength, wear-resistant TPU-sheathed cable, characterized in that, The cable comprises, from the inside out, a cable conductor, an insulation layer, a shielding layer, and a sheath layer, wherein the sheath layer is prepared using the following components in weight percentage: The composition includes 60-75% TPU resin, 10-20% reinforcing fiber, 5-15% wear-resistant filler, 0.2-0.5% antioxidant, 0.5-1% lubricant, and 5-10% flame retardant. The reinforcing fiber is one or more of glass fiber, carbon fiber, or aramid fiber; the reinforcing fiber is pretreated by plasma and cut to 0.2-0.8 mm. The flame retardant comprises microencapsulated red phosphorus and magnesium hydroxide, with a mass ratio of microencapsulated red phosphorus to magnesium hydroxide of (0.5~0.7):1; wherein the microencapsulated red phosphorus has a particle size of 5~10μm and is coated with a silane coupling agent on its surface. The lubricant contains silicone and zinc stearate, and the mass ratio of silicone to zinc stearate is (1-1.5):

1.

2. The high-strength, wear-resistant TPU-sheathed cable as described in claim 1, characterized in that, The TPU resin is thermoplastic polyurethane with a Shore A hardness of 85-95 and a molecular weight of 80,000-120,000.

3. The high-strength, wear-resistant TPU-sheathed cable as described in claim 1, characterized in that, The wear-resistant filler is one or more of silicon carbide, alumina, or silicon dioxide.

4. The high-strength, wear-resistant TPU-sheathed cable as described in claim 1, characterized in that, The antioxidant comprises hindered phenolic antioxidant 1010 and phosphite antioxidant 168, and the mass ratio of hindered phenolic antioxidant 1010 to phosphite antioxidant 168 is 1:(1-2).

5. A manufacturing process for a high-strength, abrasion-resistant TPU-sheathed cable as described in any one of claims 1-4, comprising the following steps: S1. Prepare the cable conductor; S2. Prepare single-core or multi-core insulated conductors. A single-core insulated conductor is obtained by covering the outside of a single cable conductor with an insulation layer, and a multi-core insulated conductor is obtained by stranding multiple single-core insulated conductors. S3. A braided shielding layer is wrapped around the outside of a single-core or multi-core insulated conductor to obtain a cable core; S4. Prepare the TPU sheath layer and wrap it around the outside of the cable core.

6. The manufacturing process as described in claim 5, characterized in that, Step S4 includes: S4-1. A staged feeding method is adopted. In the first stage, TPU resin and 30%~50% flame retardant are added to the internal mixer and heated and mixed at a temperature of 160-170℃ and 40~50 rpm to melt the TPU resin into a uniform matrix. In the second stage, the remaining flame retardant and other components are added and mixed at a temperature of 170~180℃ and 50~60 rpm. S4-2. The material discharged from the internal mixer enters the granulator for pelletizing. The material discharged from the granulator is then vacuum dried to obtain TPU granular material. S4-3. TPU granules are added to an extruder to prepare a TPU sheath layer. After the TPU sheath layer is discharged from the extruder, it undergoes vacuum sizing, adsorption bonding, water cooling and shaping, and traction winding to cover the outside of the cable core.

7. The manufacturing process as described in claim 6, characterized in that, The extruder includes a feeding zone, a melting zone, a mixing zone, and a die head arranged sequentially. The temperature of the feeding zone is controlled at 170~175℃, the temperature of the melting zone is controlled at 180~185℃, the temperature of the mixing zone is controlled at 185~190℃, and the temperature of the die head is controlled at 190~195℃.

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