High abrasion resistant wire cable and method of making same

Abstract

The application relates to the technical field of electric wire and cable, and provides a high-wear-resistance electric wire and cable and a preparation method thereof.The high-wear-resistance electric wire and cable comprises an inner core, a stress dispersion ring, a twisted constraint layer, a heat conduction layer, a diffusion layer and a wear-resistant layer which are coaxially sleeved from inside to outside, the wear-resistant layer comprises elastic connecting belts and flexible scales, the flexible scales are cross-connected to form a grid structure through the elastic connecting belts, and the wear-resistant layer is wrapped on the outside of the diffusion layer; and the inner core comprises a conductor core, an elastic porous filling layer and anti-torsion protrusions, and the elastic porous filling layer is filled between the conductor cores and on the outside. In the application, the wedge-shaped matching of the anti-torsion protrusions of the inner core and the meshing grooves of the stress dispersion ring, the elastic energy absorption of the spiral buffer strips, the structural reinforcement of the aramid belts of the twisted constraint layer, and the grid deformation matching of the elastic connecting belts and the flexible scales of the wear-resistant layer are combined, so that the torsional stress is gradedly dissipated, the wear damage is dispersed and buffered, the torsional life of the electric cable is greatly prolonged, and the surface wear resistance of the electric cable is greatly improved.

Description

Technical Field

[0001] The embodiments of the present invention relate to the field of wire and cable technology, specifically to a high wear-resistant wire and cable and a method for preparing the same. Background Technology

[0002] High abrasion-resistant wires and cables are widely used in complex operating environments such as industrial robotic arms, mining equipment, and rail transit traction systems. In these applications, cables must withstand frequent mechanical actions such as torsion, bending, and dragging over long periods of time, while also facing external abrasion such as equipment friction and sand and gravel abrasion. Furthermore, they must have good heat dissipation performance during high current transmission to avoid overheating failure. Therefore, stringent requirements are placed on the torsional stability, surface abrasion resistance, and structural durability of the cables.

[0003] In existing technologies, conventional wires and cables typically employ a basic structure of "conductor stranding + insulation layer wrapping + sheath protection." Their torsional resistance design largely relies on the conductor stranding process or the addition of a single elastic buffer layer, using the material's inherent flexibility to alleviate torsional stress. Abrasion protection primarily depends on thickening the rubber sheath or adding abrasion-resistant particles to the sheath surface. However, because traditional sheaths are integral structures, localized wear can quickly spread to the entire sheath surface. Furthermore, the rigid connection between the sheath and the internal structure allows wear stress to be directly transferred to the inner layer, causing stress concentration at the conductor-insulation interface. This leads to fatigue fracture of localized structures due to repeated deformation, accelerating the failure of the overall structure and making it difficult to meet the long-life requirements under complex operating conditions. Summary of the Invention

[0004] To overcome the above-mentioned defects, the present invention provides a high wear-resistant wire and cable and its preparation method, which solves the technical problem in related technologies / existing technologies that some wires and cables use an integral sheath and are rigidly connected to the inside, resulting in wear and torsional stress being directly transmitted to the inner layer, thus causing local structural fatigue fracture.

[0005] A high wear-resistant wire and cable includes an inner core, and further includes a stress dispersion ring, a stranded constraint layer, a heat-conducting layer, a diffusion layer and a wear-resistant layer coaxially arranged from the inside to the outside;

[0006] The wear-resistant layer includes elastic connecting strips and flexible scales. The flexible scales are cross-connected by the elastic connecting strips to form a grid structure, and the wear-resistant layer is wrapped around the outside of the diffusion layer.

[0007] The inner core includes a conductor core, an elastic porous filling layer, and anti-torsion protrusions. The elastic porous filling layer fills the space between and the outer side of the conductor core, and the anti-torsion protrusions are spirally distributed on the outer surface of the elastic porous filling layer.

[0008] The stress dispersion ring includes an anti-torsion support ring, a spiral buffer strip, and a meshing groove. The spiral buffer strip is fitted inside the anti-torsion support ring, and multiple meshing grooves are spirally distributed inside the spiral buffer strip. The meshing grooves are adapted to mesh with the anti-torsion protrusions of the inner core.

[0009] As a further description of the above technical solution:

[0010] The anti-torsion convex tooth has an isosceles wedge-shaped structure, with arc-shaped convex structures on the front and rear sides, and a rounded corner design at the top;

[0011] As a further description of the above technical solution:

[0012] The meshing groove of the stress dispersion ring meshes with the anti-torsion convex tooth of the inner core, and the size of the meshing groove is slightly larger than the size of the anti-torsion convex tooth.

[0013] As a further description of the above technical solution:

[0014] The stranded constraint layer includes an outer sheath and an aramid tape;

[0015] The aramid tape is spirally wound inside the outer sheath, and the outer sheath is sleeved on the outside of the anti-torsion support ring of the stress dispersion ring;

[0016] As a further description of the above technical solution:

[0017] The aramid tape is woven from 36 strands of aramid fibers at a predetermined helical angle, forming a ring-shaped mesh.

[0018] As a further description of the above technical solution:

[0019] The thermally conductive layer includes a microporous foamed rubber layer and a hollow thermally conductive column;

[0020] The hollow heat-conducting columns are spaced and embedded within the microporous foamed rubber layer, and the microporous foamed rubber layer is wrapped around the outside of the twisted constraint layer.

[0021] As a further description of the above technical solution:

[0022] The diffusion layer includes an insulating filler layer and Y-shaped thermal conductive holes;

[0023] The Y-shaped heat-conducting hole penetrates the insulating filling layer, and the insulating filling layer is sleeved on the outside of the microporous foamed rubber layer of the heat-conducting layer. The Y-shaped heat-conducting hole is connected to the hollow heat-conducting column of the heat-conducting layer.

[0024] A method for preparing a high abrasion-resistant wire and cable, applicable to any of the high abrasion-resistant wires and cables described above, comprising the following steps:

[0025] S1. Core Preparation: First, multiple strands of copper wire are twisted together to form a conductor core; then, microporous ethylene propylene diene monomer (EPDM) is extruded into the gaps and outer side of the conductor core through a three-layer co-extrusion process to form an elastic porous filling layer; simultaneously, modified cross-linked polyethylene (XLPE) is co-extruded onto the outer surface of the filling layer and integrally formed with spirally distributed isosceles wedge-shaped anti-torsional protrusions; finally, the EPDM filling layer is pre-vulcanized to fix the porous structure.

[0026] S2. Stress Dispersion Ring Preparation and Assembly: The first step is to injection mold a polyimide (PI) anti-torsion support ring and open a spiral groove on its inner side; a spiral buffer strip is made of nickel-titanium alloy (NiTi) wire reinforced hydrogenated nitrile butadiene rubber (HNBR) and fitted into the groove of the support ring; a meshing groove that matches the anti-torsion protrusion is milled on the inner side of the buffer strip; the anti-torsion protrusion of the inner core is aligned with the meshing groove of the stress dispersion ring by rotating the tooling to complete the spiral meshing assembly;

[0027] S3. Preparation of stranded constraint layer: First, cross-linked polyethylene (XLPE) is extruded on the outside of the stress dispersion ring to form an outer sheath; aramid fibers are woven into a mesh aramid tape at a predetermined helical angle using a ring braiding machine; the aramid tape is spirally wound onto the surface of the outer sheath using hot melt adhesive, and then fixed by pressure curing.

[0028] S4. Preparation of thermal conductive layer: Molten hydrogenated nitrile butadiene rubber (HNBR) is extruded through a foaming mold to form a microporous foamed rubber layer, which is wrapped around the outside of the stranded constraint layer; Before the rubber layer is vulcanized, pre-made polyimide (PI) hollow thermal conductive pillars are embedded at intervals.

[0029] S5. Diffusion layer preparation: Modified polyimide (PI) is injection molded on the outside of the thermally conductive layer to form an insulating filler layer; a custom mold with a Y-shaped core is used to simultaneously form Y-shaped thermally conductive holes that penetrate the insulating filler layer during the injection molding process to ensure that the thermally conductive holes are connected to the hollow thermally conductive pillars;

[0030] S6. Preparation and wrapping of wear-resistant layer: Thermoplastic polyurethane (TPU) is used as the elastic connecting strip and ceramicized polyurethane (PU) is used as the flexible flakes. The wear-resistant layer is cross-woven into a mesh-like wear-resistant layer by a biaxial braiding machine. The wear-resistant layer is wrapped around the outside of the diffusion layer and hot-pressed by a hot press to soften the elastic connecting strip and make it tightly adhere to the surface of the diffusion layer. It is then cooled and shaped.

[0031] S7. Overall Post-treatment: The rubber structures such as the ethylene propylene rubber filler layer, hydrogenated nitrile rubber buffer strip, and microporous foamed rubber layer are vulcanized as a whole. The plastic structures such as the polyimide support ring, cross-linked polyethylene outer layer, and modified polyimide insulation layer are annealed to eliminate internal stress. The torsional resistance, abrasion resistance, and thermal conductivity are tested by a torsion tester, an abrasion tester, and an infrared thermal imager to ensure compliance with standards.

[0032] The beneficial effects of the embodiments of the present invention are as follows:

[0033] 1. In this invention, the wedge-shaped fit between the inner core anti-torsion convex teeth and the stress dispersion ring meshing groove, the elastic energy absorption of the spiral buffer strip, the structural reinforcement of the stranded constraint layer aramid tape, and the mesh deformation fit between the wear-resistant layer elastic connecting strip and the flexible scales are achieved, thereby realizing the graded dissipation of torsional stress and the dispersion and buffering of wear damage, which greatly enhances the torsional life and surface wear resistance of the cable.

[0034] 2. In this invention, through the initial heat conduction of the inner core elastic porous filling layer, the convection assistance of the microporous foamed rubber of the heat-conducting layer and the directional heat conduction of the hollow heat-conducting column, combined with the gradient heat dissipation design of the Y-shaped heat-conducting holes in the diffusion layer, a three-layer heat dissipation path from the inside to the outside is constructed, which efficiently dissipates the heat of the conductor and ensures the thermal stability of the cable under high load conditions. Attached Figure Description

[0035] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the drawings described below are merely some exemplary embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the content of the exemplary embodiments of the present invention and these drawings without any creative effort.

[0036] Figure 1 This is a three-dimensional schematic diagram of a high wear-resistant wire and cable and its preparation method proposed in this invention;

[0037] Figure 2 This is a planar schematic diagram of a high wear-resistant wire and cable and its preparation method proposed in this invention;

[0038] Figure 3 This is a schematic diagram of the inner core structure of a high wear-resistant wire and cable and its preparation method proposed in this invention;

[0039] Figure 4 This is a schematic diagram of the stress dispersion ring structure of a high wear-resistant wire and cable and its preparation method proposed in this invention.

[0040] Figure 5 This is a schematic diagram of the stranded constraint layer in the high wear-resistant wire and cable and its preparation method proposed in this invention.

[0041] Figure 6 This is a schematic diagram of the structure of the heat-conducting layer in a high wear-resistant wire and cable and its preparation method proposed in this invention;

[0042] Figure 7 This is a schematic diagram of the wear-resistant layer of a high wear-resistant wire and cable and its preparation method proposed in this invention;

[0043] Figure 8This is a process flow diagram of a high wear-resistant wire and cable and its preparation method proposed in this invention.

[0044] In the picture:

[0045] 1. Inner core; 101. Conductor core; 102. Elastic porous filling layer; 103. Anti-torsion serrations; 2. Stress dispersion ring; 201. Anti-torsion support ring; 202. Spiral buffer strip; 203. Engaging groove; 3. Stranded constraint layer; 301. Outer sheath; 302. Aramid tape; 4. Thermal conductive layer; 401. Microporous foamed rubber layer; 402. Hollow thermal conductive column; 5. Diffusion layer; 501. Insulating filling layer; 502. Y-shaped thermal conductive hole; 6. Wear-resistant layer; 601. Elastic connecting strip; 602. Flexible scales. Detailed Implementation

[0046] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it.

[0047] To keep the drawings concise, each drawing only schematically shows the parts relevant to the invention; these do not represent the actual structure of the product. Furthermore, for ease of understanding, in some drawings, only one of components with the same structure or function is schematically shown, or only one is labeled. In this document, "one" not only means "only one," but can also mean "more than one," and "several" includes "two" and "more than two."

[0048] In this document, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0049] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0050] In the description of this embodiment, terms such as "upper," "lower," "left," and "right" are based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of description and simplification of operation, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0051] Furthermore, in the description of this application, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0052] Reference Figures 1 to 7 The present invention provides an embodiment of a high wear-resistant wire and cable, including an inner core 1, and further including a stress dispersion ring 2, a stranded constraint layer 3, a heat-conducting layer 4, a diffusion layer 5 and a wear-resistant layer 6 coaxially arranged from the inside to the outside. The layers are connected in sequence to form a functional synergistic system to ensure the performance stability of the cable under complex working conditions.

[0053] The wear-resistant layer 6 includes an elastic connecting strip 601 and flexible scales 602. The flexible scales 602 are cross-connected by the elastic connecting strip 601 to form a grid structure. The wear-resistant layer 6 is wrapped around the outside of the diffusion layer 5. The elastic connecting strip 601 adapts to the bending and twisting deformation of the cable, and the flexible scales 602 resist external friction. The grid structure disperses the local wear stress to the surrounding scales.

[0054] The inner core 1 includes a conductor core 101, an elastic porous filling layer 102, and anti-torsion protrusions 103. The elastic porous filling layer 102 fills the space between and outside the conductor core 101. The conductor core 101 ensures conductivity. The elastic porous filling layer 102 buffers conductor vibration and impact and supports the anti-torsion protrusions 103. The anti-torsion protrusions 103 are spirally distributed on the outer surface of the elastic porous filling layer 102. The anti-torsion protrusions 103 have an isosceles wedge structure, with arc-shaped convex structures on the front and rear sides and a rounded corner design at the top. The spiral distribution matches the torsion direction. The arc-shaped sides convert concentrated stress into distributed pressure, and the rounded corners avoid stress concentration at the edges.

[0055] The stress dispersion ring 2 includes an anti-torsion support ring 201, a spiral buffer strip 202, and a meshing groove 203. The spiral buffer strip 202 is fitted inside the anti-torsion support ring 201. Multiple meshing grooves 203 are spirally distributed inside the spiral buffer strip 202. The meshing grooves 203 are adapted to mesh with the anti-torsion protrusions 103 of the inner core 1. The meshing grooves 203 of the stress dispersion ring 2 are meshed and connected with the anti-torsion protrusions 103 of the inner core 1. The size of the meshing grooves 203 is slightly larger than the size of the anti-torsion protrusions 103. The anti-torsion support ring 201 provides a rigid base to constrain the deformation of the buffer strip. The spiral buffer strip 202 absorbs the torsional impact energy. The meshing grooves 203 are spirally distributed and continuously contact the protrusions. The slightly larger size allows the protrusions to move slightly and disperse the stress.

[0056] The stranded constraint layer 3 includes an outer sheath 301 and an aramid tape 302. The aramid tape 302 is spirally wound inside the outer sheath 301, and the outer sheath 301 is sleeved on the outside of the anti-torsion support ring 201 of the stress dispersion ring 2. The aramid tape 302 is woven from 36 strands of aramid fibers at a predetermined helical angle, forming a ring-shaped mesh. The outer sheath 301 provides insulation, and the aramid tape 302, with its high strength, bears circumferential tensile and axial shear stress to prevent the structure from loosening.

[0057] The thermally conductive layer 4 includes a microporous foamed rubber layer 401 and hollow thermally conductive pillars 402. The hollow thermally conductive pillars 402 are intermittently embedded in the microporous foamed rubber layer 401, and the microporous foamed rubber layer 401 is wrapped around the outside of the twisted constraint layer 3. The microporous foamed rubber layer 401 assists in heat convection through its microporous structure and wraps around the constraint layer. The hollow thermally conductive pillars 402 quickly capture and directionally conduct heat.

[0058] The diffusion layer 5 includes an insulating filler layer 501 and a Y-shaped heat-conducting hole 502. The Y-shaped heat-conducting hole 502 penetrates the insulating filler layer 501, and the insulating filler layer 501 is sleeved on the outside of the microporous foamed rubber layer 401 of the heat-conducting layer 4. The Y-shaped heat-conducting hole 502 is connected to the hollow heat-conducting column 402 of the heat-conducting layer 4. The insulating filler layer 501 assists in heat diffusion and provides insulation, while the Y-shaped heat-conducting hole 502 increases the heat dissipation area and connects with the hollow heat-conducting column 402 to form a continuous heat dissipation path. I will use a document editor to better support the editing needs of long content.

[0059] Reference Figures 1 to 7 The present invention provides an embodiment of a high wear-resistant wire and cable, including an inner core 1, and further including a stress dispersion ring 2, a stranded constraint layer 3, a heat-conducting layer 4, a diffusion layer 5 and a wear-resistant layer 6 coaxially arranged from the inside to the outside. The layers are connected in sequence to form a functional synergistic system to ensure the stable performance of the cable under complex working conditions.

[0060] The wear-resistant layer 6 includes an elastic connecting strip 601 and flexible scales 602. The flexible scales 602 are cross-connected by the elastic connecting strip 601 to form a grid structure. The wear-resistant layer 6 is wrapped around the outside of the diffusion layer 5. The elastic connecting strip 601 adapts to the bending and twisting deformation of the cable, and the flexible scales 602 resist external friction. The grid structure disperses the local wear stress to the surrounding scales.

[0061] The inner core 1 includes a conductor core 101, an elastic porous filling layer 102, and anti-torsion protrusions 103. The elastic porous filling layer 102 fills the space between and on the outside of the conductor core 101. The conductor core 101 ensures conductivity. The elastic porous filling layer 102 buffers conductor vibration and impact and supports the anti-torsion protrusions 103. The anti-torsion protrusions 103 are spirally distributed on the outer surface of the elastic porous filling layer 102. The anti-torsion protrusions 103 have an isosceles wedge structure, with arc-shaped convex structures on the front and rear sides and a rounded corner design at the top. The spiral distribution matches the torsion direction, and the arc-shaped sides convert concentrated stress into distributed pressure. The rounded corners prevent stress concentration at the edges.

[0062] The stress dispersion ring 2 includes an anti-torsion support ring 201, a spiral buffer strip 202, and a meshing groove 203. The spiral buffer strip 202 is fitted inside the anti-torsion support ring 201. Multiple meshing grooves 203 are spirally distributed inside the spiral buffer strip 202. The meshing grooves 203 are adapted to mesh with the anti-torsion protrusions 103 of the inner core 1. The meshing grooves 203 of the stress dispersion ring 2 are meshed with the anti-torsion protrusions 103 of the inner core 1. The size of the meshing grooves 203 is slightly larger than the size of the anti-torsion protrusions 103. The anti-torsion support ring 201 provides a rigid base to constrain the deformation of the buffer strip. The spiral buffer strip 202 absorbs torsional impact energy. The spirally distributed meshing grooves 203 are in continuous contact with the protrusions. The slightly larger size allows for minor misalignment of the protrusions to disperse stress.

[0063] The stranded constraint layer 3 includes an outer sheath 301 and an aramid tape 302. The aramid tape 302 is spirally wound inside the outer sheath 301, and the outer sheath 301 is sleeved on the outside of the anti-torsion support ring 201 of the stress dispersion ring 2. The aramid tape 302 is woven from 36 strands of aramid fibers at a predetermined helical angle, forming a ring-shaped mesh. The outer sheath 301 provides insulation, and the aramid tape 302, with its high strength, bears circumferential tensile and axial shear stress to prevent the structure from loosening.

[0064] The heat-conducting layer 4 includes a microporous foamed rubber layer 401 and hollow heat-conducting columns 402. The hollow heat-conducting columns 402 are intermittently embedded in the microporous foamed rubber layer 401, and the microporous foamed rubber layer 401 is wrapped around the outside of the stranded constraint layer 3. The microporous foamed rubber layer 401 assists in heat convection through its microporous structure and wraps around the constraint layer. The hollow heat-conducting columns 402 quickly capture and directionally conduct heat.

[0065] The diffusion layer 5 includes an insulating filler layer 501 and a Y-shaped heat-conducting hole 502. The Y-shaped heat-conducting hole 502 penetrates the insulating filler layer 501, and the insulating filler layer 501 is sleeved on the outside of the microporous foamed rubber layer 401 of the heat-conducting layer 4. The Y-shaped heat-conducting hole 502 is connected to the hollow heat-conducting column 402 of the heat-conducting layer 4. The insulating filler layer 501 assists in heat diffusion and achieves insulation. The Y-shaped heat-conducting hole 502 increases the heat dissipation area and is connected to the hollow heat-conducting column 402 to form a continuous heat dissipation path.

[0066] Reference Figure 8A method for preparing a high abrasion-resistant wire and cable, applicable to any of the above-mentioned high abrasion-resistant wires and cables, includes the following steps:

[0067] S1. Preparation of inner core 1: First, multiple strands of copper wire are twisted together to form a conductor core 101; through a three-layer co-extrusion process, microporous ethylene propylene rubber (EPDM) is extruded into the gaps and outer side of the conductor core 101 to form an elastic porous filling layer 102; simultaneously, modified cross-linked polyethylene (XLPE) is co-extruded on the outer surface of the filling layer, and is integrally formed with spirally distributed isosceles wedge-shaped anti-torsion protrusions 103; finally, the ethylene propylene rubber filling layer is pre-vulcanized to fix the porous structure.

[0068] S2. Preparation and assembly of stress dispersion ring 2: Step 1: Injection mold a polyimide (PI) anti-torsion support ring 201 and open a spiral groove on its inner side; make a spiral buffer strip 202 by reinforcing hydrogenated nitrile butadiene rubber (HNBR) with nickel-titanium alloy (NiTi) wire and fit it into the groove of the support ring; mill a meshing groove 203 on the inner side of the buffer strip that matches the anti-torsion protrusion 103; align the anti-torsion protrusion 103 of the inner core 1 with the meshing groove 203 of the stress dispersion ring 2 by rotating the tooling to complete the spiral meshing assembly;

[0069] S3. Preparation of stranded constraint layer 3: First, cross-linked polyethylene (XLPE) is extruded on the outside of stress dispersion ring 2 to form outer sheath 301; aramid fibers are woven into mesh aramid tape 302 at a predetermined helical angle using a ring braiding machine; the aramid tape 302 is spirally wound onto the surface of outer sheath 301 by hot melt adhesive and fixed by pressure curing treatment.

[0070] S4. Preparation of thermal conductive layer 4: Molten hydrogenated nitrile butadiene rubber (HNBR) is extruded through a foaming mold to form a microporous foamed rubber layer 401, which is wrapped around the outside of the stranded constraint layer 3; Before the rubber layer is vulcanized, pre-made polyimide (PI) hollow thermal conductive columns 402 are embedded at intervals.

[0071] S5. Preparation of diffusion layer 5: Modified polyimide (PI) is injection molded on the outside of thermally conductive layer 4 to form insulating filler layer 501; using a custom mold with Y-shaped core, Y-shaped thermal conductive holes 502 penetrating the insulating filler layer 501 are simultaneously formed during the injection molding process to ensure that the thermal conductive holes are connected to the hollow thermal conductive pillar 402.

[0072] S6. Preparation and wrapping of wear-resistant layer 6: Thermoplastic polyurethane (TPU) is used as the elastic connecting strip 601 and ceramicized polyurethane (PU) is used as the flexible flakes 602. The wear-resistant layer 6 is cross-woven into a mesh shape by a biaxial braiding machine. The wear-resistant layer 6 is put on the outside of the diffusion layer 5 and the elastic connecting strip 601 is softened and tightly attached to the surface of the diffusion layer 5 by hot pressing. The layer is then cooled and shaped.

[0073] S7. Overall Post-treatment: The rubber structures such as the ethylene propylene rubber filler layer, hydrogenated nitrile rubber buffer strip, and microporous foamed rubber layer 401 are vulcanized as a whole. The plastic structures such as the polyimide support ring, cross-linked polyethylene outer layer 301, and modified polyimide insulation layer are annealed to eliminate internal stress. The torsional resistance, abrasion resistance, and thermal conductivity are tested by a torsion tester, an abrasion tester, and an infrared thermal imager to ensure compliance with standards.

[0074] Working principle: When the cable is subjected to torsional force, the anti-torsion protrusions 103 spirally distributed on the outer surface of the inner core 1 precisely mesh with the meshing grooves 203 on the spiral buffer strip 202 inside the stress dispersion ring 2. Because the meshing grooves 203 are slightly larger than the anti-torsion protrusions 103, the protrusions can move slightly within the groove during torsion, converting the concentrated torsional stress into distributed contact pressure. At the same time, the spiral buffer strip 202 undergoes elastic deformation, further absorbing impact energy. The anti-torsion support ring 201, as a rigid base, constrains the excessive deformation of the buffer strip. On this basis, the annular mesh aramid tape 302, woven from 36 strands of aramid fibers at a predetermined helical angle in the stranded constraint layer 3, is wound inside the outer sheath 301. With its ultra-high strength, it bears the circumferential tensile stress and axial shear stress, preventing the intermediate layer structure from loosening and further enhancing the overall torsional stability.

[0075] Regarding wear resistance, the flexible scales 602 of the wear-resistant layer 6 directly resist external friction. Their high hardness reduces physical wear. The elastic connecting strip 601 cross-connects the scales to form a grid structure. When the cable is bent or twisted, the connecting strip adapts to the structural deformation through elastic deformation, preventing the scales from breaking due to hard contact. At the same time, it disperses the local wear stress to the surrounding scales, thereby extending the wear-resistant life.

[0076] During cable operation, heat is transferred through the elastic porous filling layer 102 of the inner core 1 to the microporous foamed rubber layer 401 of the heat-conducting layer 4—the microporous structure provides a heat conduction channel and also assists in heat dissipation with air convection; then, the high thermal conductivity of the hollow heat-conducting columns 402 quickly captures heat and conducts it axially. Subsequently, the heat enters the diffusion layer 5 and diffuses to both sides through the Y-shaped heat-conducting holes 502 that penetrate the insulating filling layer 501: the Y-shaped structure increases the heat dissipation area, and combined with the low thermal resistance characteristics of the modified polyimide insulating filling layer 501, accelerates the dissipation of heat to the external environment. Finally, the heat is further exchanged with the outside air through the mesh gaps of the wear-resistant layer 6.

[0077] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A high wear-resistant wire and cable, comprising an inner core (1), characterized in that: It also includes a stress dispersion ring (2), a stranded constraint layer (3), a heat-conducting layer (4), a diffusion layer (5) and a wear-resistant layer (6) that are coaxially sleeved from the inside to the outside. The wear-resistant layer (6) includes an elastic connecting strip (601) and flexible scales (602). The flexible scales (602) are cross-connected by the elastic connecting strip (601) to form a grid structure, and the wear-resistant layer (6) is wrapped around the outside of the diffusion layer (5). The inner core (1) includes a conductor core (101), an elastic porous filling layer (102), and anti-torsion protrusions (103). The elastic porous filling layer (102) fills the space between and outside the conductor core (101), and the anti-torsion protrusions (103) are spirally distributed on the outer surface of the elastic porous filling layer (102). The stress dispersion ring (2) includes an anti-torsion support ring (201), a spiral buffer strip (202), and a meshing groove (203). The spiral buffer strip (202) is fitted inside the anti-torsion support ring (201), and multiple meshing grooves (203) are spirally distributed inside the spiral buffer strip (202). The meshing grooves (203) are adapted to mesh with the anti-torsion protrusions (103) of the inner core (1). The heat-conducting layer (4) includes a microporous foamed rubber layer (401) and hollow heat-conducting columns (402). The hollow heat-conducting columns (402) are intermittently embedded in the microporous foamed rubber layer (401), and the microporous foamed rubber layer (401) is wrapped around the outside of the twisted constraint layer (3). The diffusion layer (5) includes an insulating filler layer (501) and a Y-shaped heat-conducting hole (502). The Y-shaped heat-conducting hole (502) penetrates the insulating filler layer (501), and the insulating filler layer (501) is sleeved on the outside of the microporous foamed rubber layer (401) of the heat-conducting layer (4). The Y-shaped heat-conducting hole (502) is connected to the hollow heat-conducting column (402) of the heat-conducting layer (4).

2. The high wear-resistant wire and cable according to claim 1, characterized in that: The anti-torsion convex tooth (103) is an isosceles wedge-shaped structure with arc-shaped convex structures on the front and rear sides and a rounded corner design at the top.

3. The high abrasion-resistant wire and cable according to claim 1, characterized in that: The meshing groove (203) of the stress dispersion ring (2) is meshed with the anti-torsion protrusion (103) of the inner core (1), and the size of the meshing groove (203) is slightly larger than the size of the anti-torsion protrusion (103).

4. The high wear-resistant wire and cable according to claim 1, characterized in that: The stranded constraint layer (3) includes an outer sheath (301) and an aramid tape (302); The aramid tape (302) is spirally wound inside the outer sheath (301), and the outer sheath (301) is sleeved on the outside of the anti-torsion support ring (201) of the stress dispersion ring (2).

5. The high abrasion-resistant wire and cable according to claim 4, characterized in that: The aramid tape (302) is woven from 36 strands of aramid fibers at a predetermined helical angle, forming a ring-shaped mesh.

6. A method for preparing a high abrasion-resistant wire and cable, applicable to the high abrasion-resistant wire and cable according to any one of claims 1-5, comprising the following steps: S1. Preparation of inner core (1): First, multiple strands of copper wire are twisted together to form a conductor core (101); through a three-layer co-extrusion process, microporous ethylene propylene rubber (EPDM) is extruded in the gaps and on the outside of the conductor core (101) to form an elastic porous filling layer (102); simultaneously, modified cross-linked polyethylene (XLPE) is co-extruded on the outer surface of the filling layer, and is integrally formed with spirally distributed isosceles wedge-shaped anti-torsion protrusions (103); finally, the elastic porous filling layer (102) is pre-vulcanized to fix the porous structure; S2. Preparation and assembly of stress dispersion ring (2): First step: injection molding of polyimide (PI) anti-torsion support ring (201) and opening a spiral groove on its inner side; making a spiral buffer strip (202) of nickel-titanium alloy (NiTi) wire reinforced hydrogenated nitrile butadiene rubber (HNBR) and fitting it into the groove of the support ring; milling a meshing groove (203) that matches the anti-torsion protrusion (103) on the inner side of the buffer strip; aligning the anti-torsion protrusion (103) of the inner core (1) with the meshing groove (203) of the stress dispersion ring (2) by rotating the tooling to complete the spiral meshing assembly; S3. Preparation of stranded constraint layer (3): First, cross-linked polyethylene (XLPE) is extruded on the outside of the stress dispersion ring (2) to form an outer layer (301); aramid fibers are woven into a mesh aramid tape (302) at a predetermined helical angle using a ring braiding machine; the aramid tape (302) is spirally wound onto the surface of the outer layer (301) by hot melt adhesive and fixed by pressure curing treatment; S4. Preparation of thermal conductive layer (4): Molten hydrogenated nitrile butadiene rubber (HNBR) is extruded through a foaming mold to form a microporous foamed rubber layer (401), which is wrapped around the outside of the twisted constraint layer (3); Before the rubber layer is vulcanized, pre-made polyimide (PI) hollow thermal conductive columns (402) are embedded at intervals. S5. Preparation of diffusion layer (5): Modified polyimide (PI) is injection molded on the outside of the thermally conductive layer (4) to form an insulating filler layer (501); Using a custom mold with a Y-shaped core, a Y-shaped thermally conductive hole (502) penetrating the insulating filler layer (501) is simultaneously formed during the injection molding process to ensure that the thermally conductive hole is connected to the hollow thermally conductive column (402); S6. Preparation and wrapping of wear-resistant layer (6): Thermoplastic polyurethane (TPU) is used as elastic connecting strip (601) and ceramic polyurethane (PU) is used as flexible flakes (602). The wear-resistant layer (6) is cross-woven into a mesh shape by a biaxial braiding machine. The wear-resistant layer (6) is wrapped around the outside of the diffusion layer (5). The elastic connecting strip (601) is softened and tightly adhered to the surface of the diffusion layer (5) by hot pressing with a hot press. The layer is then cooled and shaped. S7. Overall post-treatment: The elastic porous filling layer (102) made of microporous ethylene propylene rubber, the spiral buffer strip (202) reinforced with nickel-titanium alloy wire and hydrogenated nitrile rubber as the substrate, and the microporous foamed rubber layer (401) are vulcanized as a whole. The polyimide anti-torsion support ring (201), the cross-linked polyethylene outer layer (301), and the insulating filling layer (501) made of modified polyimide are annealed to eliminate internal stress. The torsional performance, abrasion performance and thermal conductivity are tested by torsion testing machine, abrasion testing machine and infrared thermal imager respectively to ensure that they meet the standards.

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