Silica gel fiberglass cable and method of making same

Abstract

This application provides a silicone fiberglass cable and its preparation method. A fiberglass bundle is split into several bundles using a splitting device. A broadening technique is employed to disperse the fiberglass filaments within each bundle. The surface of the fiberglass filaments is treated with a coupling agent. The fibers are then fully wetted and penetrated in silicone impregnation. Multiple silicone-coated fiberglass filaments are then pultruded and vulcanized to form silicone fiberglass wire. The silicone fiberglass wire is then impregnated with a silicone rubber adhesive, wet-wound to anchors at both ends, and wet-wound axially and radially between the two anchors, forming a silicone fiberglass core after vulcanization. Finally, a high-temperature vulcanized silicone molding process is used to integrally mold and cover the core, forming end wrapping, a core sheath, and sheds. The resulting silicone fiberglass cable possesses the load-bearing and internal / external insulation functions required for suspension and tension composite insulators in power transmission lines.

Description

Technical Field

[0001] This invention relates to the field of silicone wire technology, specifically to a silicone glass fiber cable and its preparation method. Background Technology

[0002] Fiber-reinforced composite cable for bearing axial loads in related technologies consists of several parallel fiber-reinforced composite wires, with anchors at both ends and an outer protective layer. When this cable is used for insulation and mechanical fixing of high-voltage transmission lines between conductors and towers, the transmission lines operate in harsh natural environments such as high voltage, strong winds and heavy rain, and sudden icefalls, which can lead to swaying and jumping. Therefore, the cable used between the conductor and tower must not only be able to withstand alternating bending and torsional loads, but also possess reliable internal and external insulation properties.

[0003] However, existing structural fiber-reinforced composite cables still have the following problems: Existing structural fiber-reinforced composite cables do not possess the corresponding load-bearing and insulation properties of existing composite insulators. Under high voltage, alternating bending, and torsional loads, radial forces are generated within the cable core. Since the cable core lacks radial fiber reinforcement, long-term operation leads to radial cracking and loosening of the core. This not only causes the cable to lose its advantage as a whole composite material bearing the load, but also, under high voltage, radial cracking and loosening can lead to through-insulation breakdown within the cable core, resulting in loss of internal insulation performance. The outer protective layer of the cable does not form the necessary external insulation for operation in high-voltage environments, i.e., the creepage distance composed of the shed strings. The open connection between the cable ends and the anchor lacks sealing performance, making it prone to partial discharge, corona discharge, and other insulation degradation under the erosion of rainwater and moisture. Furthermore, the contact surface between the cable core and the anchor is not fixed, easily causing displacement and friction between the contact surface when the cable swings or jumps. The reinforcing fibers within the cable are worn down, leading to a loss of load-bearing capacity over long-term operation.

[0004] In another existing technology, the press-fit composite insulator, the internal insulation and load-bearing function are performed by glass fiber reinforced epoxy resin composite pultruded rods (FRP), commonly known as epoxy glass fiber rods. Due to its open molecular structure, epoxy resin allows water molecules to diffuse rapidly and be absorbed in large quantities. Simultaneously, micropores or cracks within the material further accelerate the moisture absorption process. When the composite material is subjected to low stress, the matrix epoxy resin may reach its failure stress, causing cracks to initiate and propagate within the material. Glass fiber, on the other hand, has surface defects that easily absorb moisture and exhibit surface cracks. The absorbed moisture promotes the propagation of surface cracks in the glass fiber and increases the surface conductivity of the glass. Epoxy glass fiber rods belong to a fully brittle composite material system; under the composite effect, their performance combines the characteristics of epoxy resin and glass fiber, mainly exhibiting hygroscopicity and a tendency to crack. Under long-term alternating loads, the cracks continuously propagate, exacerbating internal air gap discharge. Once the outer sheath is damaged, moisture and water seep in, and the epoxy fiberglass rod will quickly become saturated with water. The moisture will spread rapidly, leading to a decrease in internal insulation performance and even hydrolysis of the epoxy resin. This can cause the epoxy fiberglass rod to rot and break, lose its insulation and load-bearing functions, and result in sudden failure.

[0005] Therefore, a new type of cable is needed for insulating and mechanically securing high-voltage transmission lines between transmission conductors and towers. Summary of the Invention

[0006] To address the aforementioned technical problems, this application provides a silicone fiberglass thread and a silicone fiberglass cable, as well as a method for preparing the same.

[0007] One embodiment of this application provides a method for preparing silicone glass fiber cables, comprising the following steps:

[0008] The preparation steps of silicone glass fiber thread are as follows: First, the glass fiber bundles are split, and then the split glass fibers are subjected to surface treatment, first impregnation, and pultrusion molding to obtain linear silicone glass fiber composite materials. These composite materials are then vacuum treated and vulcanized to obtain silicone glass fiber threads. Second, the silicone glass fiber threads are impregnated in an impregnation tank containing silicone rubber adhesive, resulting in silicone glass fiber threads that are fully wetted and coated by the adhesive. Third, the wet winding step involves fixing two anchors at intervals on a dedicated double-anchor wet winding machine, with the connection direction of the two anchors being axial. First, the threads are wound along the axial direction on both anchors… Between the anchor grooves, silicone fiberglass wire obtained from the second impregnation step is axially wet-wound; then, at least one layer of silicone fiberglass wire is wet-wound around the bundle of silicone fiberglass wire formed by the axial wet winding between the two anchors. After vacuum treatment and vulcanization, the silicone fiberglass wires are bonded together, as are the silicone fiberglass wires and the galvanized layer on the anchor surface, forming the core of the silicone fiberglass cable. The cable forming step involves using a molding process to cover the core of the silicone fiberglass cable with a silicone rubber protective sleeve and a skirt surrounding the silicone rubber protective sleeve; thus, the silicone fiberglass cable is obtained.

[0009] In one embodiment, the silicone rubber adhesive liquid comprises R-624Z liquid silicone rubber.

[0010] In one embodiment, during the wet winding step, at least one layer of silicone fiberglass wire is wet-wound between the wire grooves of the two anchors along the axial direction. Then, the clamps of the anchors are used to clamp and gather the wire bundle formed by the axial wet winding of the silicone fiberglass wire, so that the wire bundle of silicone fiberglass wire between the outlet ports of the two clamps is aggregated into one.

[0011] In one embodiment, during the wet winding step, after the axial wire harness is wound, at least one layer of silicone fiberglass is wet-wound around the circumferential end of the clamp to form a thrust shoulder at the end of the clamp.

[0012] In one embodiment, the original bundle splitting process in the silicone glass fiber filament preparation step specifically includes: using a splitting device to split the original glass fiber bundle into several glass fiber bundles, controlling the number of glass fiber filaments in the bundle so that the glass fiber filaments in the bundle can be fully wetted and impregnated in the subsequent first impregnation process.

[0013] In one embodiment, the first impregnation process specifically includes: introducing the glass fiber filaments in the bundle obtained after surface treatment into an impregnation tank containing silicone rubber glass fiber impregnation liquid, so that the surface of each glass fiber is fully wetted and penetrated by the silicone rubber glass fiber impregnation liquid, so that the surface of the glass fiber filaments in the bundle is wrapped by the silicone rubber glass fiber impregnation liquid.

[0014] In one embodiment, in the first impregnation process, the silicone rubber impregnation solution comprises GMX-8600TG liquid silicone rubber.

[0015] In one embodiment, after the silicone fiberglass thread preparation step and before the second impregnation step, the surfaces of the silicone fiberglass thread and the anchor are cleaned respectively, and the surface of the silicone fiberglass thread and the anchor is treated with a coupling agent respectively.

[0016] In one embodiment, during the silicone fiberglass cable molding step, a molding and overmolding process is used to cover the silicone fiberglass cable core to form a silicone rubber protective sleeve. This process also includes using high-temperature vulcanized silicone rubber to fill the gaps between the silicone fiberglass wires and between the silicone fiberglass wires and the anchor, so as to achieve an overall seal between the silicone rubber protective sleeve and the core.

[0017] One embodiment of this application provides a silicone fiberglass cable, which is prepared using the aforementioned method for preparing silicone fiberglass cables.

[0018] This application provides a silicone fiberglass wire and a silicone fiberglass cable, and a method for preparing the same, including a silicone fiberglass wire preparation step, a second impregnation step, a wet winding step, and a cable forming step. In the wet winding step, at least one layer of silicone fiberglass wire is wound axially, and at least one layer is also wet-wound circumferentially around the bundle of silicone fiberglass wire formed by the axial wet winding. This process allows the resulting cable to withstand certain loads in both the axial and radial directions, giving the cable the ability to withstand alternating bending and torsional loads. Furthermore, because the surface of the silicone fiberglass wire is impregnated with silicone rubber adhesive in the second impregnation step, the contacting silicone fiberglass wires and the silicone fiberglass wires and anchors will bond tightly during the wet winding step, further improving load-bearing capacity and internal insulation performance. Additionally, in the cable forming step, a molding process is used to cover the core with a silicone rubber protective sleeve, and a skirt is arranged around the periphery of the silicone rubber protective sleeve, which can improve the external insulation performance of the cable. Attached Figure Description

[0019] Figure 1 The anchor used in the embodiments of this application;

[0020] Figure 2 The clamp used in the embodiments of this application;

[0021] Figure 3 This is a schematic cross-sectional view of an anchor and clamp axially wet-wound silicone fiberglass wire in an embodiment of this application;

[0022] Figure 4 The embodiments of this application show dye penetration patterns on silicone glass fiber cores; wherein, a, b, c, d, e, f, g, and h are experimental patterns for immersion in dye for 5 min, 10 min, 15 min, 30 min, 1.5 h, 5 h, 6.5 h, and 18.5 h, respectively.

[0023] Figure 5 The cable prepared in Example 2 of this application;

[0024] Figure 6 for Figure 5 The diagram shows a partial cross-sectional view of the cable.

[0025] Figure 7 for Figure 5 The diagram shows the exploded structure of the cable.

[0026] Reference numerals: silicone fiberglass thread-1, anchor-2, clamp-3, clamp outlet-4, cable-5, axially wound silicone fiberglass-51, circumferentially wound silicone fiberglass-52, thrust shoulder-7, protective sleeve-8, umbrella skirt-9. Detailed Implementation

[0027] The load-bearing capacity of crimp-fit ​​composite insulators relies on the interference fit between the end fittings and the epoxy fiberglass rods. When the outer wall of the fitting is compressed, its inner cavity undergoes elastic deformation at the contact surface with the epoxy fiberglass rod, generating radial pressure. Under axial load, this pressure is converted into friction between the contact surfaces, preventing relative displacement. Notably, this surface friction is transmitted to the reinforcing fibers only through the interfacial adhesion between the epoxy resin and the fiberglass, ultimately resulting in the fibers bearing the primary axial load. However, this load-bearing mechanism has inherent drawbacks: its performance is highly dependent on the state of the steel / epoxy and epoxy / fiberglass interfaces, as well as the integrity of the epoxy resin matrix.

[0028] In practical engineering applications, several technical bottlenecks exist: First, the crimping quality is extremely sensitive to tolerances; a 60% increase in tolerance leads to an 11% decrease in pull-out force. However, due to the difference in machining precision between pultruded fiberglass rods and fittings, manual grinding assembly is necessary. Second, the effective friction contact surface can only be expanded by increasing the axial length, but this uneconomically increases the overall size of the insulator. More seriously, material aging during long-term operation deteriorates the stress state of the contact surface, and moisture intrusion caused by sheath damage can trigger epoxy resin hydrolysis, ultimately leading to sudden decay and fracture of the composite insulator. Furthermore, existing epoxy fiberglass rods lack radial reinforcement, making them prone to cracking under dynamic loads such as galloping.

[0029] This technology also faces critical risks of interface failure: on the one hand, the bonding interface between the epoxy fiberglass rod and the silicone rubber sheath loses its moisture-proof protection function due to bonding failure; on the other hand, the pressing process involves many parameters that are difficult to quantify (such as the amount of plastic deformation of the fittings and the amount of elastic deformation of the resin), making it difficult to achieve intelligent production. These factors have collectively led to the fact that existing technologies have remained in a workshop-style production mode for decades, facing significant challenges in terms of reliability, process control, and economy.

[0030] Therefore, this application provides a silicone glass fiber cable 5 and its preparation method to solve the above problems.

[0031] The embodiments of this application provide a method for preparing silicone glass fiber cable 5. Please refer to [the relevant documentation]. Figure 1-3 and Figure 5-7 The preparation method of silicone glass fiber cable 5 includes the following steps: silicone glass fiber filament 1 preparation step, second impregnation step, wet winding step, and cable 5 forming step.

[0032] The preparation steps of silicone glass fiber filament 1 include: splitting the original glass fiber bundle, then performing surface treatment, first impregnation and pultrusion on the split glass fibers in sequence, and then vacuum treatment and vulcanization to obtain silicone glass fiber filament 1.

[0033] The second impregnation step includes: immersing the silicone fiberglass wire 1 in an impregnation tank containing a silicone rubber adhesive solution to obtain a silicone fiberglass wire 1 that is fully wetted and permeated by the silicone rubber adhesive solution and is covered by it.

[0034] The wet winding step includes: fixing two anchors 2 at intervals on a special wet winding machine for double anchors, with the connection direction of the two anchors being axial; firstly, axially wet winding is performed between the grooves of the two anchors 2 using silicone fiberglass filaments 1 obtained after the second impregnation step; then, at least one layer of silicone fiberglass filaments 1 is wet-wound around the bundle of silicone fiberglass filaments 1 formed by the axial wet winding between the two anchors 2; then, after vacuum treatment and vulcanization, the silicone fiberglass filaments 1 are bonded together with each other and with the zinc plating layer on the surface of the anchors 2, to obtain the core of the silicone fiberglass cable 5.

[0035] The forming steps of the cable 5 include: using a molding and overmolding process, a layer of silicone rubber protective sleeve 8 is wrapped around the core of the silicone fiberglass cable 5, and a skirt 9 is arranged around the silicone rubber protective sleeve 8; thus, the silicone fiberglass cable 5 is obtained.

[0036] This application impregnates the surface of the silicone fiberglass wire 1 with a silicone rubber adhesive in a second impregnation step. In the wet winding step, at least one layer of silicone fiberglass wire is wound along the axial direction defined by the two anchors 2. Then, at least one layer of silicone fiberglass wire 1 is wound circumferentially around the bundle of silicone fiberglass wire 1 formed by the axial wet winding. During this process, because the surface of the silicone fiberglass wire 1 has silicone rubber adhesive, the contacting silicone fiberglass wires 1 and the silicone fiberglass wire 1 and the anchors 2 are tightly bonded to each other, eliminating wear between the silicone fiberglass wires 1 and between the silicone fiberglass wire 1 and the anchors 2. It can also eliminate defective interfaces caused by gaps, improving the mechanical and insulation properties of the cable 5. When the cable 5 is used for insulation and mechanical fixing of high-voltage transmission lines between transmission conductors and towers, the circumferentially wound silicone fiberglass wire 1 can enhance the resistance of the transmission conductor to the radial component force generated by the alternating bending and torsion of the cable 5 when it gallops or jumps. In addition, by using a molding process to coat the core with a layer of silicone rubber protective sleeve 8 and a skirt 9 that surrounds the silicone rubber protective sleeve 8, the internal and external insulation performance of the cable 5 can be further improved. The skirt 9 can also meet the creepage distance required for the silicone fiberglass cable 5 to form external insulation when operating in high voltage scenarios.

[0037] Furthermore, in the preparation of silicone glass fiber filaments, the surface of the glass fibers needs to be fully wetted and coated with silicone rubber, which is the basis for forming a complete and defect-free interface bond. Therefore, it is necessary to select a fiber bundle with an appropriate number of monofilaments to ensure that each glass fiber is completely impregnated with silicone rubber. This application uses a bundle splitting device to divide the original glass fiber bundle into several glass fiber bundles, facilitating the full wetting and impregnation of the glass fiber filaments in the subsequent first impregnation process, and ensuring they are coated with the silicone rubber glass fiber impregnation solution. This allows for sufficient contact between the silicone rubber and the glass fiber, resulting in a high-performance silicone glass fiber filament 1.

[0038] The bonding performance at the interface between silicone rubber and glass fiber is a key factor determining the insulation and load-bearing properties of composite materials. In the process of pultruding glass fiber bundles encapsulated in silicone rubber impregnation liquid, the fibers are pretreated with an organosilane surface treatment agent. This causes the silanol groups and silanoxy groups on the fiber surface to undergo hydrolysis and condensation reactions, forming chemical bonds. Simultaneously, the reactive groups at the other end of the silane can crosslink with the silicone rubber molecular chains, thereby achieving a strong interfacial bond.

[0039] Studies have shown that the chemical bonding interface formed between the silane coupling agent and the organic resin matrix can reach a thickness of 200 nm. Although this value is relatively small, compared to glass fibers with a diameter of approximately 10 μm, the interface region still accounts for about 8% of the total fiber volume. This interface structure has multiple functional characteristics: firstly, the organosilane coating on the surface of the direct untwisted roving can act as both a protective layer and a binder; secondly, this interface layer can effectively prevent fiber wear, improve sliding performance, reduce static electricity buildup, and simultaneously ensure good spreadability of the resin during impregnation.

[0040] The glass fiber used in the embodiments of this application is an alkali-free glass fiber "direct untwisted yarn", designated EC13-2400 glass fiber. More specifically, it can be the same as the alkali-free fiber used in patent CN101093741B.

[0041] In the embodiments of this application, the diameter of the silicone fiberglass filament 1 is 0.3-0.7 mm, and the tensile strength of the silicone fiberglass filament 1 is greater than 130 N.

[0042] In the embodiments of this application, the beam splitting equipment in the original beam splitting process includes an air jet beam splitter or an electrostatic beam splitting device.

[0043] Among them, the air jet bundle splitter does not directly contact the fibers, which can reduce mechanical friction damage, and the high-speed airflow can quickly separate the fiber bundles, improving the uniformity of the bundle splitting. It is also suitable for fibers of different fineness and length. The electrostatic bundle splitter has strong controllability of electrostatic force, which can achieve more uniform fiber dispersion, reduce fiber entanglement, and also reduce mechanical friction.

[0044] The embodiments of this application provide a silicone glass fiber filament 1, which is prepared by the aforementioned method. The silicone glass fiber filament 1 includes a coating layer that is coated on the surface of the glass fiber filament by a silicone rubber glass fiber impregnation liquid; and a silicone rubber glass fiber impregnation liquid that penetrates into and fills the gaps between the glass fiber filaments, and after vacuum treatment and vulcanization, it is connected to the coating layer as a whole.

[0045] It should be noted that when performing circumferential wet winding in this application, it is not only possible to perform wet winding in a direction perpendicular to the axial direction, but also to perform wet winding at a certain angle. Similarly, cross-wet winding can also be performed to improve the ability to cope with the radial component forces generated by bending and torsion in different directions and at different angles.

[0046] In the embodiments of this application, the silicone rubber adhesive liquid includes R-624Z liquid silicone rubber, which is manufactured by Zhonglan Chenguang Chemical Research and Design Institute.

[0047] In the embodiments of this application, during the wet winding step, at least one layer of silicone fiberglass filament 1 is wet-wound axially between the wire grooves of the two anchors 2. Then, the clamps of the anchors 2 are used to clamp and gather the wire bundle formed by the axial wet winding of the silicone fiberglass filament 1, so that the wire bundle of silicone fiberglass filament 1 between the outlet ports of the two clamps 3 is aggregated into one. The inner cavity of the clamp 3 is trumpet-shaped. After being clamped and gathered by the clamps 3, the axially wet-wound silicone fiberglass filament 1 is circular at the outlet port of the clamp.

[0048] Please refer to Figure 5 In the wet winding step, after the axial wire harness winding is completed, at least one layer of silicone fiberglass 1 is wet-wound circumferentially at the outlet end 4 of the clamp to form a thrust shoulder 7 at the outlet end 4 of the clamp. The axially wound silicone fiberglass 51 and the circumferentially wound silicone fiberglass 52 are as follows... Figure 7 As shown in the image.

[0049] The formation of the thrust shoulder 7 can further improve the stress condition of the core of the cable 5 during use and reduce the stress concentration at the junction of the core and the anchor when the fixed conductor dances or jumps.

[0050] like Figure 3 As shown, the use of clamp 3 helps to integrate the wet-wound silicone fiberglass wire 1, making the silicone fiberglass wire 1 more tightly and regularly arranged, and improving the mechanical properties of the cable 5.

[0051] In this application, a clamp 3 is used to shrink the wire bundle formed by wet-wound silicone fiberglass wire 1 into a cylindrical shape. Preferably, the silicone fiberglass wire 1 with a relatively thin diameter (0.3-0.7 mm) is used for wet winding. When the thinner diameter silicone wire is wet-wound and overlapped, the gaps between the wires are smaller, making it easier to fill with the secondary impregnation of the silicone rubber adhesive, forming a gapless cylindrical core. When the thicker diameter silicone wire is wet-wound and overlapped, the gaps between the wires are larger, making it difficult to completely fill with the adhesive, easily resulting in residual gaps in the core, affecting insulation performance, and causing poor cylindrical integrity.

[0052] In this application, the number of layers of circumferential wet winding should meet the requirements for resisting radial forces generated by bending and torsion. To avoid radial cracking and loosening of the core of the cable 5 due to radial forces, each layer is wet-wound in opposite directions at intervals to meet the bending requirements of different directions and angles. The rotation direction of wet winding and the angle of the silicone fiberglass wire 1 are obtained from the fatigue test data of the silicone cable 5 core under bending and torsion.

[0053] In the silicone glass fiber filament preparation process, the original bundle splitting process specifically includes: using a splitting device to split the original glass fiber bundle into several glass fiber bundles, controlling the number of glass fiber filaments in the bundle so that the glass fiber filaments in the bundle can be fully wetted and impregnated in the subsequent first impregnation process.

[0054] The surface treatment process specifically includes: using a broadening technique to disperse the glass fiber filaments within the bundle; applying a silane coupling agent to the dispersed glass fiber filaments for surface treatment; and then drying.

[0055] It should be noted that different manufacturers use different surface protectants to treat the surface of glass fibers during the production process. Therefore, in the preparation of silicone glass fiber yarn, different silane coupling agents are required for surface treatment of glass fibers prepared by different manufacturers. For example, at least one of vinyltriethoxysilane, γ-aminopropyltriethoxysilane, γ-glycidyl ether propyltrimethoxysilane, γ-(methacrylate)propyltrimethoxysilane, and γ-mercaptopropyltrimethylsilane can be used.

[0056] The first impregnation process specifically includes: introducing the glass fiber filaments in the bundle obtained after surface treatment into an impregnation tank containing silicone rubber glass fiber impregnation liquid, so that the surface of each glass fiber is fully wetted and penetrated by the silicone rubber glass fiber impregnation liquid, so that the surface of the glass fiber filaments in the bundle is wrapped by the silicone rubber glass fiber impregnation liquid.

[0057] In the first impregnation process, the silicone rubber impregnation solution includes GMX-8600TG liquid silicone rubber, which is manufactured by Zhonglan Chenguang Chemical Research and Design Institute.

[0058] After the silicone fiberglass thread preparation step and before the second impregnation step, the surfaces of the silicone fiberglass thread and the anchor are cleaned respectively, and the surface of the silicone fiberglass thread 1 and the anchor are treated with coupling agent respectively.

[0059] Cleaning the surfaces of the silicone fiberglass wire 1 and the anchor 2 and treating them with a coupling agent helps the silicone rubber adhesive to firmly bond the silicone fiberglass wires 1 together and the interface between the anchor 2 and the silicone fiberglass wire 1 during the second impregnation process, reducing interface defects.

[0060] In the molding step of silicone fiberglass cable 5, a molding and overmolding process is adopted. When the silicone fiberglass cable 5 core is covered to form a silicone rubber protective sleeve 8, high-temperature vulcanized silicone rubber is also used to fill the gaps between silicone fiberglass wires 1 and between silicone fiberglass wires 1 and anchors 2, so as to achieve overall sealing of the core with the silicone rubber protective sleeve.

[0061] In one embodiment of this application, a monolithic injection molding process is used to fill high-temperature vulcanized silicone rubber between the silicone fiberglass filaments 1 and the gaps between the silicone fiberglass filaments 1 and the anchor 2. Specifically, in the monolithic injection molding process, the injection pressure is as high as 126 MPa and the temperature is as high as 160°C. Under this high temperature and high pressure, the high-temperature vulcanized silicone rubber is filled in a fluid state between the silicone fiberglass filaments 1 and the gaps between the silicone fiberglass filaments 1 and the anchor 2.

[0062] It should be noted that high-temperature silicone rubber in a fluid state can fully contact the microscopically uneven phases to form a dense and firm bonding interface, thereby achieving overall sealing.

[0063] The presence of any gaps between structures within cable 5 will affect the overall insulation and mechanical properties of cable 5. This application reduces the presence of gaps in the structure by filling these gaps with silicone rubber.

[0064] An embodiment of this application provides a silicone glass fiber cable 5, which is prepared using the aforementioned preparation method.

[0065] Example 1

[0066] The preparation of silicone fiberglass thread in this embodiment includes the following steps:

[0067] The original glass fiber bundle splitting step involves using a comb-needle splitting machine to separate the original glass fiber bundle into several glass fiber bundles. The number of glass fibers in each bundle is controlled to ensure that all glass fiber filaments in each bundle are fully wetted and impregnated in the subsequent first impregnation process. The parameters of the comb-needle splitting machine should be adjusted according to standard operating procedures for those skilled in the art to achieve the desired effect.

[0068] Surface treatment steps: A broadening technique is used to disperse the glass fiber filaments within the bundle. The dispersed glass fiber filaments are then surface-treated with a vinyltriethoxysilane coupling agent and dried at 110-120℃ for 20-30 minutes.

[0069] First impregnation step: The glass fiber bundle obtained from the surface treatment step is introduced into an impregnation tank containing GMX-8600TG liquid silicone rubber, so that the surface of each glass fiber is fully wetted and impregnated by GMX-8600TG liquid silicone rubber, and the surface of the glass fiber filaments in the bundle is wrapped with GMX-8600TG liquid silicone rubber.

[0070] Molding steps: The glass fiber bundles obtained in the first impregnation step, which are wrapped in GMX-8600TG liquid silicone rubber, are pultruded, and then subjected to vacuum treatment and vulcanization to obtain silicone glass fiber yarn. The vulcanization temperature is 160-180℃, and the vulcanization time is 10 minutes.

[0071] Example 2

[0072] Please refer to Figure 5-7 The preparation of silicone glass fiber cable 5 in this embodiment includes the following steps:

[0073] Cleaning steps: First, clean the surfaces of the silicone wire and the anchor separately, and then use vinyltriethoxysilane coupling agent to treat the surfaces of the silicone fiberglass wire and the anchor separately to obtain the cleaned silicone fiberglass wire.

[0074] Second impregnation step: Immerse the silicone fiberglass thread in an impregnation tank containing R-624Z liquid silicone rubber for 3 minutes to obtain silicone fiberglass thread 1 that is fully wetted and impregnated by R-624Z liquid silicone rubber and covered.

[0075] Winding Steps: Two anchors are fixed at intervals on a double-anchor winding machine, with the connection direction of the two anchors being axial. First, axial wet winding is performed between the wire grooves of the two anchors using silicone fiberglass thread 1 obtained after the second impregnation step. Then, the clamp 3 of the anchor 2 is used to clamp the bundle of silicone fiberglass thread formed by the axial wet winding. The outlet of the clamp 3 is circular. Next, at least one layer of silicone fiberglass thread 1 is wet-wound around the bundle of silicone fiberglass thread 1 formed by the axial wet winding between the anchors 2. Furthermore, at least one layer of silicone fiberglass thread 1 is wet-wound circumferentially at the outlet end 4 of the clamp, thereby forming a thrust shoulder 7 at the outlet end 4 of the clamp. Then, vacuum treatment and vulcanization are performed to bond the silicone fiberglass thread 1 together with each other and to the galvanized layer on the surface of the anchor 2, resulting in a silicone cable core.

[0076] The molding process of cable 5 is as follows: a layer of silicone rubber protective sleeve 8 is wrapped around the core of silicone cable 5 using a molding process, and a skirt 9 is arranged around the silicone rubber protective sleeve 8 to obtain silicone fiberglass cable 5.

[0077] Performance testing

[0078] Dye penetration tests were conducted on the silicone fiberglass wire 1 in Example 1 and the silicone fiberglass core in Example 2, according to GB / T 22079-2008, "General Definitions, Test Methods and Acceptance Criteria for Indoor and Outdoor Polymer Insulators with Nominal Voltage Higher than 1000V". The test results for silicone fiberglass wire 1 are shown in Table 1, and the test results for the core are shown in Table 2. Figure 4 As shown in Table 2.

[0079] The silicone cable core 5 in Example 2 was inspected according to GB / T 19519-2014 "Definition, Test Methods and Acceptance Criteria for Suspension and Tension Composite Insulators for AC Systems with Nominal Voltage Higher than 1000 V".

[0080] The silicone cable core of Example 2 was tested according to GB / T 35156-2017 "Fiber-reinforced composite cables for structural use 5".

[0081] The silicone cable 5 core in Example 2 was tested according to GB / T 22079-2008 "General definition, test methods and acceptance criteria for indoor and outdoor polymer insulators with nominal voltage higher than 1000V".

[0082] The silicone fiberglass cable 5 in Example 3 was tested according to GB / T 19519-2014 "Definition, Test Methods and Acceptance Criteria for Suspension and Tension Composite Insulators for AC Systems with Nominal Voltage Higher than 1000V".

[0083] Table 1

[0084] 15min Sample A: 5mm; Sample B: 6mm 30min Sample A: 5mm; Sample B: 6mm 90min Sample A: 6mm; Sample B: 6mm 4h Sample A: 6mm; Sample B: 6mm 9.5h Sample A: 6mm; Sample B: 6mm 19h Sample A: 6mm; Sample B: 6mm

[0085] *Sample A and Sample B are two silicone glass fiber threads tested, with identical manufacturing processes and lengths.

[0086] Table 2

[0087] 5min no 10min no 15min no 30min no 1.5h no 5h no 6.5h no 18.5h no

[0088] As shown in Table 1, in the dye penetration test of silicone fiberglass wire 1, the dye level was approximately 3 mm high. With the sample leaning against the beaker wall, the depth of immersion in the dye was close to 5 mm. During the test, at 15 minutes, the penetration depths of the two fiberglass samples were 5 mm and 6 mm, respectively; at 90 minutes, the penetration depths of both samples were 6 mm, and remained constant throughout the subsequent test period. Therefore, after removing the influence of the initial dye wetting effect, the dye penetration depth in the sample was approximately 1 mm throughout the entire test, which meets the requirements of the standard GB / T 22079-2008 General Definitions, Test Methods and Acceptance Criteria for Indoor and Outdoor Polymer Insulators with Nominal Voltage Higher than 1000V.

[0089] As shown in Table 2 and Figure 4 As shown, at the 15-minute mark of this test, the dye only penetrated through the loosely wrapped outer layer of the mandrel; the denser inner portion remained undyed. At the end of the test, although most of the dye appeared on the upper surface of the mandrel, some of the vertical, loosely wrapped outer fiberglass remained undyed, indicating that the dye had not penetrated the interior of the mandrel. Throughout the test, the sample conformed to the standards specified in GB / T 22079-2008 General Definitions, Test Methods and Acceptance Criteria for Indoor and Outdoor Polymer Insulators with Nominal Voltage Higher than 1000V.

[0090] The silicone cable 5-core prepared in Example 2 of this application meets the test requirements of GB / T 19519-2014 "Definition, Test Methods and Acceptance Criteria for Suspension and Tension Composite Insulators for AC Systems with Nominal Voltage Higher than 1000V".

[0091] The silicone cable 5 core prepared in Example 2 of this application conforms to the test standard of GB / T 35156-2017 "Fiber Reinforced Composite Cables for Structural Use 5".

[0092] The silicone cable 5-core prepared in Example 2 of this application conforms to GB / T 22079-2008 "General definition, test methods and acceptance criteria for indoor and outdoor polymer insulators with nominal voltage higher than 1000V".

[0093] The silicone fiberglass cable 5 prepared in Example 2 of this application conforms to GB / T 19519-2014 "Definition, test methods and acceptance criteria for suspension and tension composite insulators for AC systems with nominal voltage higher than 1000V".

[0094] Through a high-temperature, high-pressure molding process, high-temperature vulcanized silicone rubber (HTV) completely fills all gaps between the core and anchor 2, forming a dense protective layer after vulcanization. This structure not only achieves overall sealing, effectively preventing the intrusion of corrosive media such as moisture and salt spray, but also eliminates relative displacement between components through the high elasticity of silicone rubber, avoiding fiber wear due to friction.

[0095] The stable and reliable interface of the silicone-glass fiber cable 5 is the greatest guarantee that its insulation and load-bearing performance meet the composite insulator standard (GB / T19519-2014). The silicone-glass fiber cable 5 has three types of bonding interfaces: between silicone and glass fiber, between silicone fibers of different densities, and between silicone and the galvanized layer of the metal anchor. Chemical bonds are formed at the interface, representing the strongest bonding force. For example, silicone rubber and glass fiber form a dense bond interface through chemical bonding (such as Si-O-Si covalent bonds) and interlocking of surface micro-nano structures; the core and silicone sheath are interfaces between silicone fibers of different densities, where cross-linking occurs through interdiffusion, forming chemical bonds and creating a dense bond without an interface; chemical bonds are also formed at the interface between silicone and the galvanized layer of the metal anchor. This stable and reliable bonding interface is the greatest reliability performance of the silicone-glass fiber cable 5. Furthermore, the manufacturing methods of silicone-glass fiber wire and silicone-glass fiber cable 5 are suitable for intelligent large-scale production, which helps to avoid human error, improve quality, and reduce costs.

[0096] The above examples illustrate the present invention only to aid in understanding it and are not intended to limit the scope of the invention. Those skilled in the art can make various simple deductions, modifications, or substitutions based on the principles of this invention.

Claims

1. A method for preparing silicone glass fiber cables, characterized in that, Includes the following steps: Silicone glass fiber filament preparation steps: the glass fiber bundles are split, and then the split glass fibers are subjected to surface treatment, first impregnation and pultrusion molding in sequence to obtain linear silicone glass fiber composite material. The silicone glass fiber composite material is then subjected to vacuum treatment and vulcanization to obtain silicone glass fiber filament. The second impregnation step is to impregnate the silicone fiberglass wire in an impregnation tank containing silicone rubber adhesive liquid to obtain silicone fiberglass wire that is fully wetted and covered by the silicone rubber adhesive liquid. Wet winding step: Two anchors are fixed at intervals on a special wet winding machine for double anchors. The connection direction of the two anchors is axial. First, axial wet winding is performed between the grooves of the two anchors using the silicone fiberglass thread obtained after the second impregnation step. Then, at least one layer of silicone fiberglass thread is wet-wound around the bundle of silicone fiberglass thread formed by the axial wet winding between the two anchors. After vacuum treatment and vulcanization, the silicone fiberglass threads are bonded together and bonded to the zinc plating layer on the surface of the anchors to form a whole, thus obtaining the core of the silicone fiberglass cable. Cable forming steps: Using a molding and overmolding process, a layer of silicone rubber protective sleeve is wrapped around the core of the silicone fiberglass cable, and a skirt is arranged around the periphery of the silicone rubber protective sleeve; thus, the silicone fiberglass cable is obtained.

2. The preparation method according to claim 1, characterized in that, The silicone rubber adhesive liquid includes R-624Z liquid silicone rubber.

3. The preparation method according to claim 1, characterized in that, In the wet winding step, at least one layer of silicone fiberglass wire is wet-wound between the wire grooves of the two anchors along the axial direction. Then, the clamps of the anchors are used to clamp and gather the wire bundle formed by the axial wet winding of the silicone fiberglass wire, so that the wire bundle of silicone fiberglass wire between the outlet ports of the two clamps is aggregated into one.

4. The preparation method according to claim 3, characterized in that, In the wet winding step, after the axial wire harness is wound, at least one layer of the silicone fiberglass wire is wet-wound circumferentially at the outlet end of the clamp to form a thrust shoulder at the outlet end of the clamp.

5. The preparation method according to claim 1, characterized in that, In the silicone fiberglass thread preparation step, the original bundle splitting process specifically includes: using a splitting device to split the original fiberglass bundle into several fiberglass bundles, controlling the number of fiberglass filaments in the bundle so that the fiberglass filaments in the bundle can be fully wetted and impregnated in the subsequent first impregnation process.

6. The preparation method according to claim 5, characterized in that, The first impregnation process specifically includes: introducing the glass fiber filaments in the bundle obtained by the surface treatment into an impregnation tank containing silicone rubber glass fiber impregnation liquid, so that the surface of each glass fiber is fully wetted and penetrated by the silicone rubber glass fiber impregnation liquid, so that the surface of the glass fiber filaments in the bundle is wrapped by the silicone rubber glass fiber impregnation liquid.

7. The preparation method according to claim 6, characterized in that, In the first impregnation process, the impregnation solution used includes GMX-8600TG liquid silicone rubber.

8. The preparation method according to claim 1, characterized in that, After the silicone fiberglass thread preparation step and before the second impregnation step, the surfaces of the silicone fiberglass thread and the anchor are cleaned respectively, and the surface of the silicone fiberglass thread and the anchor is treated with a coupling agent respectively.

9. The preparation method according to claim 1, characterized in that, In the silicone fiberglass cable molding step, a molding and overmolding process is used to cover the silicone fiberglass cable core to form a silicone rubber protective sleeve. This process also includes using high-temperature vulcanized silicone rubber to fill the gaps between the silicone fiberglass wires and between the silicone fiberglass wires and the anchor, so as to achieve an overall seal between the silicone rubber protective sleeve and the core.

10. A silicone fiberglass cable, characterized in that, The silicone fiberglass cable is prepared using the preparation method described in any one of claims 1-9.

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