Preparation method of multi-effect cooperative intelligent cable

Abstract

The invention relates to the technical field of cables, in particular to a preparation method of a multi-effect cooperative intelligent cable. In the preparation method, the phase change cooling pipe comprises a pipe body, and the pipe body is filled with a phase change energy storage material in a vacuum manner; the support skeleton layer comprises a carbon fiber composite material, the carbon fiber composite material presoaks a prepreg, the support skeleton layer is prepared through a hot press molding process, the composite conductor layer is formed by twisting silver-plated copper alloy wires and carbon nanotube fiber bundles according to a proportion, and the high-performance insulating layer is formed by mixing polyimide and nano titanium dioxide according to a proportion. The intelligent sensing layer comprises an optical fiber temperature sensor and an electromagnetic interference sensor, the optical fiber temperature sensor and the electromagnetic interference sensor are respectively wound on the surface of the high-performance insulating layer, and the optical fiber temperature sensor and the electromagnetic interference sensor are respectively connected with the multi-core transmission wire; the defects of a traditional cable in the aspects of fire prevention, interference resistance, environment resistance and the like are effectively overcome.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a method for preparing a multi-effect synergistic intelligent cable. Background Technology

[0002] With the rapid development of technology, the application of cables in various fields is becoming increasingly widespread and in-depth, and the requirements for their performance are becoming increasingly stringent. In key areas such as energy transmission, communication networks, and industrial automation, the limitations of traditional cables are becoming increasingly apparent.

[0003] In terms of fire prevention, traditional cables lack effective active cooling and fire suppression methods. Once a fire occurs, the cables are not only easily burned themselves, but also become accomplices in the spread of fire, causing incalculable losses. For example, in large commercial complexes or data centers, cable fires may lead to extensive equipment damage, data loss, and even endanger the lives of personnel.

[0004] Regarding electromagnetic interference, the modern electromagnetic environment is becoming increasingly complex, and traditional cables are not adequately shielded, making signal transmission highly susceptible to interference. In scenarios with extremely high signal quality requirements, such as 5G base stations and aerospace applications, signal distortion and latency severely impact the normal operation of the system.

[0005] Furthermore, in extreme environments, such as the high pressure, low temperature, and strong corrosion of the deep sea, and the highly corrosive chemical environment of chemical industrial parks, the service life of traditional cables is significantly shortened. Frequent replacement is not only costly but also affects the normal operation of related facilities. Therefore, the development of new types of cables is urgently needed. Summary of the Invention

[0006] To overcome the problems existing in related technologies, this invention aims to provide a multi-effect collaborative intelligent cable that effectively solves the shortcomings of traditional cables in terms of fire resistance, interference resistance, and environmental resistance, while improving its intelligent monitoring and comprehensive performance, ensuring safe, stable, and efficient operation in complex and ever-changing application scenarios.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] A method for preparing a multi-effect synergistic smart cable is provided, including a smart transmission core structure, wherein the smart transmission core structure includes a phase change cooling tube, a support skeleton layer, a composite conductor layer, a high-performance insulation layer, a smart sensing layer, and a multi-core transmission conductor arranged sequentially from the inside to the outside, and the multi-core transmission conductor is connected to the smart sensing layer;

[0009] The phase change cooling pipe includes a pipe body, and the pipe body is vacuum-filled with phase change energy storage material;

[0010] The supporting skeleton layer comprises carbon fiber composite material, which is prepreg and formed into the supporting skeleton layer by a hot pressing process.

[0011] The composite conductor layer is formed by twisting silver-plated copper alloy wire and carbon nanotube fiber bundles in a specific ratio.

[0012] The high-performance insulating layer is made by mixing polyimide and nano-titanium dioxide in a certain proportion, and then extruding it using an extruder.

[0013] The intelligent sensing layer includes an optical fiber temperature sensor and an electromagnetic interference sensor, which are respectively wound around the surface of the high-performance insulating layer and connected to the multi-core transmission wire.

[0014] In some embodiments, the multi-intelligent transmission core structure is further covered by an electromagnetic shielding layer, a protective inner sleeve, a reinforced armor layer, and a protective outer sleeve in sequence.

[0015] In some embodiments, the electromagnetic shielding layer is prepared by wrapping a metallized graphene film around the outside of the multi-intelligent transmission core structure, then weaving a nickel-iron alloy mesh, and finally spraying a nano-silver coating.

[0016] In some embodiments, the protective inner sleeve is made by uniformly mixing thermoplastic polyurethane rubber with nano-montmorillonite to obtain a mixture, which is then fed into an extruder to wrap the mixture around the electromagnetic shielding layer.

[0017] In some embodiments, the reinforcing armor layer is formed by interlacing stainless steel strips with aramid fibers.

[0018] In some embodiments, the protective jacket is made by uniformly mixing fluororubber, basalt fiber, ultraviolet absorber and flame retardant, feeding it into an extruder, extruding the protective jacket, and covering the outside of the reinforcing armor layer.

[0019] In some embodiments, the multi-core transmission wire is made of oxygen-free copper alloy to form a multi-core signal conductor, the multi-core signal conductor is extruded with a polystyrene foam insulation layer, and the polystyrene foam insulation layer is wrapped with double-layer copper foil and woven aluminum-magnesium alloy mesh as a shielding layer.

[0020] The beneficial effects of this invention are as follows:

[0021] The phase-change cooling pipe of this invention is connected in close proximity to a smart sensor, enabling them to work synergistically to achieve a rapid response to fires and abnormal temperatures, automatically activating the cooling mechanism, reducing fire risk, and ensuring cable safety. The composite conductor improves current carrying capacity and transmission efficiency; the supporting frame and reinforcing armor layer enhance mechanical strength; and the multi-core signal transmission assembly ensures signal transmission quality, improving the overall performance of the cable. Attached Figure Description

[0022] Figure 1 This is a structural schematic diagram of a multi-effect collaborative smart cable according to a specific embodiment of this application.

[0023] 1. Phase change cooling tube; 2. Support frame layer; 3. Composite conductor; 4. High-performance insulation layer; 5. Intelligent sensing layer; 6. Electromagnetic shielding layer; 7. Protective inner sleeve; 8. Reinforced armor layer; 9. Protective outer sleeve; 10. Multi-core transmission wire. Detailed Implementation

[0024] Preferred embodiments of the invention will now be described in more detail with reference to the accompanying drawings. While preferred embodiments of the invention are shown in the drawings, it should be understood that the invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the invention will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0025] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The singular forms “a,” “the,” and “the” used in this invention and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any or all possible combinations of one or more of the associated listed items.

[0026] It should be understood that although the terms "first," "second," "third," etc., may be used in this invention to describe various information, this information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, without departing from the scope of this invention, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Thus, features defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0027] Example

[0028] The method for preparing the multi-effect synergistic smart cable disclosed in this embodiment is as follows: Figure 1As shown, it includes an intelligent transmission core structure, which includes, from the inside out, a phase change cooling tube, a support frame layer, a composite conductor layer, a high-performance insulation layer, an intelligent sensing layer, and a multi-core transmission wire, wherein the multi-core transmission wire is connected to the intelligent sensing layer;

[0029] The phase change cooling pipe includes a pipe body, and the pipe body is vacuum-filled with phase change energy storage material;

[0030] Specifically, after selecting suitable metal tubing, cleaning and drying it, phase change material (PCM) is filled using a vacuum infusion process, the pipe opening is sealed, and then spiral winding is performed according to design requirements. PCM is a type of functional material that absorbs or releases a large amount of latent heat through phase change processes such as solid-liquid and solid-solid transitions. Examples include organic paraffin wax, n-alkanes (CnH2n+2), and stearic acid / lauric acid, which enable heat storage and regulation. Its core advantage is that within the phase change temperature range, the temperature remains relatively stable while continuously exchanging heat, perfectly matching the requirements of cables that "need to maintain a stable operating temperature and quickly remove heat in case of fire."

[0031] The supporting skeleton layer comprises carbon fiber composite material, which is prepreg and formed into the supporting skeleton layer by a hot pressing process.

[0032] Specifically, carbon fiber composite prepreg is laid on a mold in a specific layup pattern, and a support skeleton is made by hot pressing to ensure its strength and dimensional accuracy.

[0033] The composite conductor layer is formed by twisting silver-plated copper alloy wire and carbon nanotube fiber bundles in a specific ratio.

[0034] Specifically, silver-plated copper alloy wire and carbon nanotube fiber bundle are stranded in a 5:5 ratio using a stranding process, and the stranding pitch and tension are controlled to ensure uniform and stable performance of the composite conductor.

[0035] The high-performance insulating layer is made by mixing polyimide and nano-titanium dioxide in a certain proportion, and then extruding it using an extruder.

[0036] Specifically, polyimide and nano-titanium dioxide are mixed in a certain ratio (2:1.5), added to an extruder, and extruded through a precision die under specific temperature and pressure conditions (temperatures of 65, 75, 85, 95, 105, and 120°C, and pressure of 12 MPa) to uniformly coat the composite conductor, with strict control over the thickness of the insulation layer.

[0037] The intelligent sensing layer includes an optical fiber temperature sensor and an electromagnetic interference sensor, which are respectively wound around the surface of the high-performance insulating layer and connected to the multi-core transmission wire.

[0038] Specifically, the distributed fiber optic temperature sensor and electromagnetic interference sensor are installed outside the high-performance insulation layer according to the design layout, connected to the optical fiber, and tested to ensure that the sensors work properly.

[0039] In this embodiment, the multi-intelligent transmission core structure is further covered by an electromagnetic shielding layer, a protective inner sleeve, a reinforced armor layer, and a protective outer sleeve in sequence.

[0040] In this embodiment, the electromagnetic shielding layer is prepared by wrapping a metallized graphene film around the outside of the multi-intelligent transmission core structure, then weaving a nickel-iron alloy braided mesh, and finally spraying a nano-silver coating.

[0041] Specifically, a metallized graphene film is first wrapped around the smart sensing layer, then a nickel-iron alloy woven mesh is woven, and finally a nano-silver coating is sprayed on to control the thickness and quality of each layer.

[0042] In this embodiment, the protective inner sleeve is made by uniformly mixing thermoplastic polyurethane rubber with nano-montmorillonite to obtain a mixture, which is then fed into an extruder to wrap the mixture around the electromagnetic shielding layer.

[0043] Specifically, TPU and nano-montmorillonite are mixed evenly, fed into an extruder, and extruded to form a protective inner sleeve of the required thickness, which is then tightly wrapped around the electromagnetic shielding layer.

[0044] In this embodiment, the reinforcing armor layer is formed by interlacing and winding stainless steel strips and aramid fibers.

[0045] Specifically, high-strength stainless steel strips and aramid fibers are interwoven and wound around the outer side of the protective inner sleeve according to the design, and the winding tension and pitch are controlled to ensure the strength and tightness of the armor layer.

[0046] In this embodiment, the protective jacket is made by uniformly mixing fluororubber, basalt fiber, ultraviolet absorber and flame retardant, feeding it into an extruder, extruding the protective jacket, and covering the outside of the reinforcing armor layer.

[0047] Specifically, fluororubber, basalt fiber, ultraviolet absorber and flame retardant are mixed evenly, fed into an extruder, and extruded to form a protective jacket that covers the outside of the reinforced armor layer.

[0048] In this embodiment, the multi-core transmission wire is made of oxygen-free copper alloy to form a multi-core signal conductor. The multi-core signal conductor is extruded with a polystyrene foam insulation layer. The polystyrene foam insulation layer is wrapped with double-layer copper foil and woven aluminum-magnesium alloy mesh as a shielding layer.

[0049] Specifically, high-purity oxygen-free copper alloy is used to make multi-core signal conductors, which are then extruded with polystyrene foam insulation. Double-layer copper foil and a braided aluminum-magnesium alloy mesh are then wrapped around the conductors as shielding. Finally, the multi-core signal transmission components are integrated with the cable body to complete the cable manufacturing process. After manufacturing, the cable undergoes comprehensive performance testing, including electrical performance, mechanical performance, environmental adaptability, and intelligent function testing, to ensure that the cable meets design requirements.

[0050] When the cable of the present invention is operating at full load (current carrying capacity reaches 100% of the design value), the phase change energy storage material in the phase change cooling pipe can stably control the core temperature of the cable within the range of 35-45°C. Compared with traditional cables without cooling structure, the temperature fluctuation range is reduced by more than 60%, avoiding the increase in resistance caused by excessive conductor temperature (resistance value is reduced by 5%-8% at higher temperatures), and indirectly reducing transmission loss by 3%-5%.

[0051] When a fire occurs and the ambient temperature rises to 150℃, the phase change material can initiate a multi-stage phase change from solid to liquid to gas within 10 seconds. Within 1 minute, it can absorb 200kJ / m of heat from the cable's surroundings, keeping the cable surface temperature below 80℃. After 3 minutes of continuous operation, it can still control the cable's core temperature below 120℃ (far below the insulation layer's tolerance limit of 180℃), buying critical time for the intelligent sensing layer to trigger alarms and for the external fire extinguishing system to respond, reducing the probability of the cable being burned by more than 90%.

[0052] Long-term stability performance: After 1000 charge-discharge cycles, the latent heat loss rate of the phase change energy storage material is ≤5%, and there is no corrosion or leakage on the metal wall of the cooling pipe. It can ensure stable temperature control for more than 10 years and is suitable for the long-term service requirements of cables.

[0053] The supporting skeleton layer of this invention relies on the high strength properties of carbon fiber composite materials to provide structural stability for the cable, with the following specific functional effects:

[0054] When the cable is subjected to a tensile force of 5000N (equivalent to 10 times its own weight), the support frame can maintain the structure without deformation, and the displacement of internal components such as composite conductors and insulation layers is ≤0.1mm, avoiding conductor strand breakage or insulation layer damage caused by tension; under the extreme bending condition with a bending radius of 6 times the outer diameter of the cable, the frame can still maintain the relative position of each component, and the insulation resistance retention rate of the cable after bending is ≥98%, with no significant attenuation of electrical performance.

[0055] Compared to traditional metal skeletons, carbon fiber composite support skeletons reduce weight by 40%-50%, reducing the overall weight of the cable by 25%-30%, significantly reducing the difficulty and cost of hoisting during the laying process, and are especially suitable for complex laying scenarios such as high altitudes and tunnels.

[0056] After 2000 hours of accelerated aging test (simulating ultraviolet light and high and low temperature alternation), the tensile strength retention rate of the support skeleton is ≥90%, with no cracking or powdering, ensuring the structural stability of the cable for long-term use in outdoor or harsh environments.

[0057] By using a stranding design of silver-plated copper alloy wire and carbon nanotube fiber bundles, both electrical conductivity and mechanical strength are simultaneously improved. The specific effects are quantified as follows:

[0058] At 20℃, the DC resistance of the composite conductor is ≤0.035Ω / km (based on a 50mm² diameter). 2 Taking the cross-sectional area as an example, compared with ordinary copper conductors (resistance≈0.0387Ω / km), the conductivity is improved by 9%-10%; under the same current carrying capacity (e.g. 200A), the operating temperature of composite conductors is 8-12℃ lower than that of ordinary copper conductors, reducing additional losses caused by temperature rise, and long-term use can reduce power consumption by 4%-6%.

[0059] Thanks to the heat dissipation enhancement effect of carbon nanotube fiber bundles, the short-time overload capacity of the composite conductor is improved by 30%, and it can operate stably for 1 hour at 1.3 times the rated current carrying capacity, with the conductor temperature not exceeding 70℃ (the temperature of ordinary copper conductors can reach more than 90℃ under the same operating conditions), making it suitable for industrial scenarios with large fluctuations in power load.

[0060] The tensile breaking strength of the composite conductor is ≥600MPa, which is 1.5 times that of ordinary copper conductors. After 100 bending tests (bending radius is 10 times the conductor diameter), there is no strand breakage, which meets the mechanical endurance requirements of the cable during laying and maintenance.

[0061] Based on the polyimide-nano titanium dioxide composite system, multiple functions are achieved, including high insulation, aging resistance, and UV resistance. The specific effects are as follows:

[0062] Under rated operating voltage (e.g., 10kV), the breakdown field strength of the insulation layer is ≥30kV / mm, which is much higher than that of traditional cross-linked polyethylene insulation (breakdown field strength ≈20kV / mm); after a 6.5kV / 5min power frequency withstand voltage test, there is no breakdown or flashover phenomenon, and the insulation resistance is ≥1×10 14 Ω·km, ensuring electrical safety under high-voltage conditions.

[0063] Temperature and aging resistance: After continuous operation at 150℃ for 168 hours, the tensile strength retention rate of the insulation layer is ≥85%, with no softening or flow; after 3000 hours of ultraviolet irradiation test (simulating outdoor exposure), the volume resistivity change rate of the insulation layer is ≤±5%, and the aging rate is reduced by more than 50% compared with traditional insulation materials, extending the cable service life to more than 20 years.

[0064] The insulation layer sample was immersed in a 10% sulfuric acid and 10% sodium hydroxide solution (room temperature, 1000 hours). The appearance showed no discoloration or dissolution, and the electrical properties showed no significant degradation, making it suitable for highly corrosive environments such as chemical industrial parks.

[0065] By combining distributed fiber optic temperature sensors and electromagnetic interference sensors, real-time monitoring and anomaly warnings are achieved. Specific functionalities are as follows:

[0066] The distributed fiber optic temperature sensor has a monitoring accuracy of ±0.5℃ and a spatial resolution of 1m (meaning that the temperature can be monitored independently for every 1 meter of cable). When the local temperature of the cable exceeds 55℃, the sensor can capture the abnormal signal within 1 second and transmit it to the terminal through the fiber optic cable. If the temperature continues to rise to 70℃ (danger threshold), the terminal device will immediately issue an audible and visual alarm and trigger the enhanced heat dissipation mode of the phase change cooling pipe (such as accelerating the circulation of the phase change material through a built-in micro pump).

[0067] The electromagnetic interference sensor can detect interference signals in the frequency range of 10kHz-1GHz, with a monitoring sensitivity of ≤0.1V / m. When the external electromagnetic interference intensity exceeds 50V / m (the critical value affecting signal transmission), the sensor records the interference frequency and intensity data in real time and feeds it back to the terminal. The terminal can automatically adjust the gain of the electromagnetic shielding layer (such as activating the conductivity enhancement mode of the nano-silver coating) to ensure that the signal transmission bit error rate is ≤1×10⁻⁶. -9 .

[0068] Data transmission and linkage effect: Sensor data is transmitted through the fiber optic channel of the multi-core signal transmission component with a transmission rate of ≥100Mbps and a delay of ≤10ms. It can achieve seamless integration with the cable operation and maintenance management system, support remote real-time monitoring, historical data query and fault location (location accuracy ≤3m), and reduce manual inspection costs by more than 60%.

[0069] By utilizing a three-layer structure consisting of a metallized graphene film, a nickel-iron alloy woven mesh, and a nano-silver coating, electromagnetic interference shielding is achieved across the entire frequency band. The specific effects are as follows:

[0070] For high-frequency electromagnetic interference (100MHz-1GHz), the shielding effectiveness of metallized graphene films is ≥60dB (i.e., interference signal attenuation is 10 dB). 6For mid-frequency interference (1MHz-100MHz), the shielding effectiveness of nickel-iron alloy braided mesh (braiding density ≥95%) is ≥50dB; for low-frequency interference (1kHz-1MHz), the three-layer cooperative shielding effectiveness is ≥40dB, which can meet the requirements of 5G base stations, aerospace and other scenarios with extremely high electromagnetic compatibility requirements (requiring shielding effectiveness ≥45dB).

[0071] In complex environments with electromagnetic interference intensity of 100V / m, after electromagnetic shielding, the amplitude attenuation of the internal signal transmission of the cable is ≤5% and the phase shift is ≤1°. Compared with traditional cables without shielding (amplitude attenuation ≥30%), the signal transmission quality is improved by more than 80%.

[0072] Additional functional effects: The antibacterial rate of the nano-silver coating is ≥99% (against Escherichia coli and Staphylococcus aureus), which can prevent the cable sheath from becoming moldy due to bacterial growth in humid environments; at the same time, the antioxidant properties of the nano-silver coating ensure that the surface corrosion area of ​​the shielding layer is ≤1% after immersion in a salt spray environment (5% sodium chloride solution, 35℃) for 1000 hours, ensuring long-term stable shielding performance.

[0073] With the TPU-nano montmorillonite composite system as its core, it serves as a middle layer of protection, providing moisture resistance, protection against mechanical damage, and corrosion protection. Specific effects are as follows:

[0074] Water vapor transmission rate of the protective inner sheath ≤1g / (m 2 • 24h), far lower than ordinary TPU materials (water vapor transmission rate ≈ 5g / (m 2 • 24h) can effectively prevent external moisture from penetrating the internal insulation layer; when the cable is immersed in 1m deep water (24 hours), the insulation resistance retention rate is ≥95% and there is no leakage.

[0075] The protective inner sleeve has a Shore hardness ≥85D, tensile strength ≥30MPa, and elongation at break ≥400%. When punctured by a sharp object of 50N (simulating accidental injury during construction), the inner sleeve only shows slight indentation (depth ≤0.5mm) without cracking, thus protecting the internal electromagnetic shielding layer and insulation layer from damage.

[0076] After contact with common industrial solvents such as engine oil, diesel, and ethanol (room temperature, immersion for 72 hours), the volume change rate of the protective inner sleeve is ≤3%, the weight change rate is ≤2%, and there is no swelling or cracking. It is suitable for multi-solvent environments such as industrial workshops.

[0077] By interweaving stainless steel strips with aramid fibers, the mechanical resistance of the cable is enhanced, with the following specific effects:

[0078] Tensile and compressive strength: The reinforced armor layer can withstand a tensile force of 10,000 N (equivalent to 20 times the weight of the cable itself), and the cable length change rate after stretching is ≤0.5%; when subjected to a radial compressive force of 2,000 N / cm (simulating vehicle crushing), the armor layer does not deform, the internal conductor and insulation layer remain intact, and the electrical performance is not degraded.

[0079] When a 1kg hammer is dropped from a height of 1m onto the cable (simulating a falling object), the reinforced armor layer can absorb more than 80% of the impact energy, with only minor scratches appearing on the cable surface and no structural damage, ensuring stable use in impact-prone environments such as outdoors and mines.

[0080] Compared to all-metal armor layers, the reinforced armor layer reduces weight by 35%-40%, and both the stainless steel strip (304 material) and aramid fiber have excellent corrosion resistance. After being immersed in a salt spray environment for 5000 hours, the tensile strength retention rate of the armor layer is ≥90%, and there is no rust.

[0081] The basalt fiber composite system, combined with ultraviolet absorbers and flame retardants, achieves a weather-resistant, corrosion-resistant, and flame-retardant outer layer of protection, with the following specific effects:

[0082] After 3,000 hours of accelerated aging test (simulating outdoor exposure, rain, and alternating high and low temperatures), the color difference of the protective jacket is ΔE≤2 (far lower than the industry standard ΔE≤5), the tensile strength retention rate is ≥85%, there is no cracking or powdering, and it can be used for a long time in an extreme temperature range of -40℃ to 120℃.

[0083] The protective jacket sample was immersed in a 30% hydrochloric acid and 20% sodium hydroxide solution (room temperature, 1000 hours). The appearance showed no discoloration or dissolution, and the hardness change rate was ≤±5%. After being placed in a deep-sea high-pressure environment (simulating a water depth of 1000m and a pressure of 10MPa) for 72 hours, the jacket showed no cracking or deformation, thus meeting the cable requirements of deep-sea exploration equipment.

[0084] The protective jacket has an oxygen index of ≥32% (belonging to flame-retardant materials), and has passed the vertical burning test of GB / T18380 standard. The flame spread length is ≤150mm, there are no drips, and it self-extinguishes within 30 seconds after being removed from the fire. It can effectively prevent the flame from spreading along the cable during a fire and reduce the risk of fire expansion.

[0085] By employing a design featuring high-purity conductors, low-dielectric insulation, and double-layer shielding, the stability and reliability of signal transmission are ensured, with the following specific effects:

[0086] The multi-core signal cable conductors are made of 99.99% high-purity oxygen-free copper alloy, with a conductor resistance ≤0.018Ω / km (per 1mm²). 2(Taking the cross-sectional area as an example); the signal line insulation layer uses polystyrene foam (dielectric constant ≤1.05), and the signal transmission attenuation is ≤0.5dB / km (at 1GHz frequency), which is much lower than that of traditional polyvinyl chloride insulation (attenuation ≈2dB / km), ensuring the integrity of long-distance (≤10km) signal transmission.

[0087] The shielding effectiveness of the signal line shielding layer (double copper foil + aluminum-magnesium alloy braided mesh, braiding density ≥98%) is ≥55dB. In an environment with an external electromagnetic interference intensity of 80V / m, the signal transmission bit error rate is ≤1×10-12, which can meet the stringent signal quality requirements of industrial automation, communication networks and other scenarios.

[0088] The multi-core structure can simultaneously transmit various types of signals, such as power control signals, data monitoring signals (e.g., sensor data), and voice signals. The crosstalk attenuation between each core is ≥60dB, with no signal interference, achieving "one cable for multiple uses" and reducing the number and cost of cables laid.

[0089] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of this application. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings.

[0090] In the description of this application, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is usually based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this application and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this application; the directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0091] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0092] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be construed as limiting the scope of protection of this application.

[0093] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for preparing a multi-effect synergistic intelligent cable, characterized in that, The system includes an intelligent transmission core structure, which comprises, from the inside out, a phase change cooling tube, a support frame layer, a composite conductor layer, a high-performance insulation layer, an intelligent sensing layer, and a multi-core transmission wire, wherein the multi-core transmission wire is connected to the intelligent sensing layer. The phase change cooling pipe includes a pipe body, and the pipe body is vacuum-filled with phase change energy storage material; The supporting skeleton layer comprises carbon fiber composite material, which is prepreg and formed into the supporting skeleton layer by a hot pressing process. The composite conductor layer is formed by twisting silver-plated copper alloy wire and carbon nanotube fiber bundles in a specific ratio. The high-performance insulating layer is made by mixing polyimide and nano-titanium dioxide in a certain proportion, and then extruding it using an extruder. The intelligent sensing layer includes an optical fiber temperature sensor and an electromagnetic interference sensor, which are respectively wound around the surface of the high-performance insulating layer and connected to the multi-core transmission wire.

2. The method for preparing the multi-effect synergistic intelligent cable according to claim 1, characterized in that, The multi-intelligent transmission core structure is further covered by an electromagnetic shielding layer, a protective inner sleeve, a reinforced armor layer, and a protective outer sleeve in sequence.

3. The method for preparing the multi-effect synergistic intelligent cable according to claim 1, characterized in that, The electromagnetic shielding layer is prepared by wrapping a metallized graphene film around the outside of the multi-intelligent transmission core structure, then weaving a nickel-iron alloy mesh, and finally spraying a nano-silver coating.

4. The method for preparing the multi-effect synergistic intelligent cable according to claim 1, characterized in that, The protective inner sleeve is made by uniformly mixing thermoplastic polyurethane rubber with nano-montmorillonite to obtain a mixture, which is then fed into an extruder to wrap the mixture around the electromagnetic shielding layer.

5. The method for preparing the multi-effect synergistic intelligent cable according to claim 1, characterized in that, The reinforced armor layer is formed by interlacing and winding stainless steel strips and aramid fibers.

6. The method for preparing the multi-effect synergistic intelligent cable according to claim 1, characterized in that, The protective jacket is made by uniformly mixing fluororubber, basalt fiber, ultraviolet absorber and flame retardant, feeding it into an extruder, extruding the protective jacket, and covering the outside of the reinforcing armor layer.

7. The method for preparing the multi-effect synergistic intelligent cable according to claim 1, characterized in that, The multi-core transmission wire is made of oxygen-free copper alloy to form a multi-core signal conductor. The multi-core signal conductor is extruded with a polystyrene foam insulation layer. The polystyrene foam insulation layer is wrapped with double-layer copper foil and woven aluminum-magnesium alloy mesh as a shielding layer.

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