Multi-layer composite-wrapped high-temperature resistant and anti-aging cable

Abstract

This invention relates to the field of cable technology and discloses a multi-layer composite-wrapped high-temperature resistant and anti-aging cable. From the inside out, the invention comprises a conductor and insulated cable core, a shielding layer, an outer insulation layer, a fire-resistant layer, a heat insulation layer, a buffer layer, an armor layer, an anti-aging layer, and an outer sheath layer. The fire-resistant layer consists of alternating layers of synthetic mica tape and ceramicized borosilicate rubber tape, forming a reliable fire barrier. The heat insulation layer utilizes gradient-pore nano-aerogel, ceramicized silicone rubber rods, and phase change capsules to achieve efficient heat insulation and structural stability. The buffer layer, combined with a composite layer, an array of alumina hollow spheres, and composite capsules, provides both mechanical buffering and auxiliary heat insulation. The armor layer uses stainless steel fiber braiding to enhance mechanical protection. The anti-aging layer is a dual-layer structure of montmorillonite composite fluororubber and an antioxidant layer, delaying thermal oxidation aging.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to multi-layer composite-wrapped high-temperature resistant and anti-aging cables. Background Technology

[0002] As the core carrier of power transmission, the high temperature resistance and anti-aging ability of power cables directly determine the long-term stable operation of the power system. In high-temperature operation scenarios such as metallurgy and chemical industry, as well as in outdoor environments that are exposed to sunlight and oxidation for a long time, the requirements for the high temperature resistance and anti-aging of cables are particularly stringent.

[0003] Regarding the above-mentioned and existing related technologies, the inventors believe that the following defects often exist: the high-temperature resistant layer of traditional cables is mostly made of a single material. Under continuous high temperature, the material is prone to thermal deformation and thermal decomposition, leading to the failure of the high-temperature resistant layer, direct exposure of the internal conductor, and subsequent short circuits, open circuits and other faults, which seriously affect the continuity of power transmission. The outer protective material of existing cables has limited resistance to ultraviolet rays and chemical corrosion. After long-term use, it is prone to cracking and embrittlement, which makes the internal structure of the cable lose effective protection, accelerates the overall aging process of the cable, and significantly shortens its service life. Summary of the Invention

[0004] The technical problem to be solved by the present invention is that the existing multi-layer composite-wrapped high-temperature and anti-aging cables have the disadvantages of high temperature resistance and anti-aging. Therefore, we propose a multi-layer composite-wrapped high-temperature and anti-aging cable.

[0005] To achieve the above objectives, this application adopts the following technical solution: a multi-layer composite-wrapped high-temperature resistant and anti-aging cable, comprising, from the inside out: a conductor, each conductor being covered with an inner insulation layer to form an insulated cable core; a shielding layer, covering the outside of the conductor, the shielding layer being composed of copper wire braided mesh and aluminum foil, the copper wire braided mesh improving mechanical strength and the aluminum foil enhancing electromagnetic shielding effect, effectively blocking external electromagnetic interference; an outer insulation layer, covering the outside of the shielding layer, the outer insulation layer being made of a composite material of modified cross-linked polyethylene and nano-silica; a fire-resistant layer, covering the outside of the outer insulation layer; and a heat insulation layer, covering the outside of the fire-resistant layer, the heat insulation layer containing multiple sets of annularly distributed heat insulation components, the heat insulation components being filled with gradient porous nano-aerogel and doped with alumina ceramic fibers, and a ceramicized core being located at the center of the heat insulation layer. The system comprises: a silicone rubber rod, with phase change capsules filling the gaps between adjacent thermal insulation components and the ceramicized silicone rubber rod; a buffer layer covering the thermal insulation layer, comprising a composite layer made of ceramicized silicone rubber and basalt fiber, with alumina hollow spheres arranged in an array, and composite capsules made of expanded vermiculite silicone rubber filling the gaps between adjacent alumina hollow spheres; an armor layer covering the buffer layer; an anti-aging layer covering the armor layer; and an outer sheath layer covering the anti-aging layer, the outer sheath layer being made of nano-reinforced rubber and incorporating a graphene carbon nanotube composite heat-conducting mesh to accelerate heat dissipation; and surface textured surfaces to increase the heat dissipation area.

[0006] Preferably, the refractory layer is composed of synthetic mica tape and ceramic borosilicate rubber tape, with the mica tape as the outer layer and the ceramic borosilicate rubber tape as the inner layer. The mica tape is coated with borosilicate resin on both sides, and the thickness of the ceramic borosilicate rubber tape is 0.3-0.5 mm.

[0007] Preferably, the armor layer is made of stainless steel fiber woven material with a stainless steel fiber diameter of 0.1-0.2 mm.

[0008] Preferably, the anti-aging layer includes montmorillonite composite fluororubber coated on the outside of the armor layer. The montmorillonite composite fluororubber is coated with an antioxidant layer, which is composed of hindered phenolic antioxidant and montmorillonite particles. The composite particles of the antioxidant layer are uniformly dispersed and cured into a continuous coating. The montmorillonite composite fluororubber itself has both weather resistance and mechanical strength.

[0009] Preferably, the inner layer of the gradient pore nano-aerogel in the heat insulation layer has a higher porosity than the outer layer, with the inner layer having a porosity of 85% and the outer layer having a porosity of 65%.

[0010] Preferably, the ceramized silicone rubber rod has a bending radius greater than its own diameter at room temperature, which balances flexibility and high-temperature rigidity, and the ceramized silicone rubber rod is sintered into ceramic at high temperature.

[0011] Preferably, the phase change capsule has a phase change point of 220°C, which can buffer high-temperature shocks through phase change heat absorption.

[0012] Preferably, the buffer pad is composed of ceramicized silicone rubber and basalt fiber composite.

[0013] Preferably, the density of the alumina hollow spheres is ≤1.5g / cm³, and the temperature resistance of the alumina hollow spheres is ≥1800℃.

[0014] Preferably, the alumina hollow sphere array improves lightweight and thermal insulation, and when the expanded vermiculite silicone rubber composite capsule is used in adjacent gaps, it can seal the gaps through the expansion effect at temperatures above 200°C.

[0015] The technical effects and advantages of this invention are as follows: In this invention, the heat insulation layer, through a composite filling of gradient porous nano-aerogel and alumina ceramic fiber, supported by a central ceramicized silicone rubber rod, and combined with phase change capsules filling the gaps, achieves efficient heat conduction blocking and buffering of localized high-temperature impacts, while ensuring structural stability under high temperatures, significantly improving the cable's adaptability to extreme high-temperature environments. The buffer layer, through the synergy of a ceramicized silicone rubber and basalt fiber composite layer, an alumina hollow sphere honeycomb array, and expanded vermiculite silicone rubber composite capsules, absorbs external mechanical impacts and seals gaps, while also helping to suppress temperature rise, effectively improving the cable's resistance to mechanical damage and thermal stress erosion. The anti-aging layer, through the weather resistance enhancement of montmorillonite composite fluororubber and the slow-release anti-aging design of the antioxidant layer, specifically delays thermal oxidation aging and resists environmental erosion, significantly improving the cable's service life under harsh conditions and achieving long-term stable operation. Attached Figure Description

[0016] The disclosure of this invention is illustrated with reference to the accompanying drawings. It should be understood that the drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings, the same reference numerals are used to refer to the same parts: Figure 1 This is a schematic diagram of the overall layered three-dimensional structure of the present invention; Figure 2 This is a schematic diagram of the overall bird's-eye view three-dimensional structure of the present invention; Figure 3 A three-dimensional structural diagram is shown to illustrate the overall structure of the present invention; Figure 4 This is a schematic diagram of the overall front view of the present invention; Figure 5 This is an enlarged structural schematic diagram of the heat insulation layer of the present invention; Figure 6 This is a three-dimensional enlarged structural diagram of the buffer pad layer of the present invention.

[0017] Legend: 1. Conductor; 2. Shielding layer; 3. Outer insulation layer; 4. Fire-resistant layer; 5. Heat insulation layer; 51. Heat insulation component; 52. Ceramicized silicone rubber round rod; 53. Phase change capsule; 6. Buffer pad layer; 61. Composite layer; 62. Alumina hollow sphere; 63. Composite capsule; 7. Armor layer; 8. Anti-aging layer; 81. Montmorillonite composite fluororubber; 82. Antioxidant layer; 9. Outer sheath layer. Detailed Implementation

[0018] It is readily understood that, based on the technical solution of this invention, those skilled in the art can propose various interchangeable structural methods and implementations without altering the essential spirit of the invention. Therefore, the following detailed embodiments and accompanying drawings are merely illustrative examples of the technical solution of this invention and should not be considered as the entirety of the invention or as limitations or restrictions on the technical solution of this invention.

[0019] Reference Figure 1-6 As shown, the present invention provides a technical solution: a multi-layer composite-wrapped high-temperature resistant and anti-aging cable, comprising, from the inside out, conductors 1, each conductor 1 covered with an inner insulation layer to form an insulated cable core; a shielding layer 2, covering the outside of conductors 1, the shielding layer 2 being composed of copper wire braided mesh and aluminum foil, the copper wire braided mesh improving mechanical strength and the aluminum foil enhancing electromagnetic shielding effect, effectively blocking external electromagnetic interference; an outer insulation layer 3, covering the outside of shielding layer 2, the outer insulation layer 3 being a composite material of modified cross-linked polyethylene and nano-silica, the nanoparticles improving insulation stability and mechanical strength at high temperatures; a fire-resistant layer 4, covering the outside of the outer insulation layer 3; and a heat insulation layer 5, covering the outside of the fire-resistant layer 4, the heat insulation layer 5 containing multiple sets of annularly distributed heat insulation components 51, the heat insulation components 51 being filled with gradient porous nano-aerogel and doped with alumina ceramic fibers, and a ceramicized silicone rubber rod 52 at the center of the heat insulation layer 5, providing heat insulation. The adjacent gaps between component 51 and the ceramicized silicone rubber rod 52 are filled with phase change capsules 53, which are sodium nitrate and potassium nitrate eutectic salts encapsulated in alumina. A buffer layer 6 covers the outside of the insulation layer 5. The buffer layer 6 includes a composite layer 61 covering the buffer layer 6. The composite layer 61 is made of a composite material of ceramicized silicone rubber and basalt fiber. Hollow alumina spheres 62 are filled in the middle of the composite layer 61, arranged in an array. The gaps between adjacent hollow alumina spheres 62 are filled with composite capsules 63, which are expanded vermiculite silicone rubber. An armor layer 7 covers the outside of the buffer layer 6. An anti-aging layer 8 covers the outside of the armor layer 7. An outer sheath layer 9 covers the outside of the anti-aging layer 8. The outer sheath layer 9 uses nano-reinforced rubber and incorporates a graphene carbon nanotube composite heat-conducting mesh to accelerate heat dissipation. The surface is provided with heat dissipation textures to increase the heat dissipation area, and it also has chemical corrosion resistance and UV resistance.

[0020] Reference Figure 1-6As shown in this embodiment: the refractory layer 4 is composed of synthetic mica tape and ceramic borosilicate rubber tape, with the mica tape as the outer layer and the ceramic borosilicate rubber tape as the inner layer. The mica tape is coated with borosilicate resin on both sides, and the thickness of the ceramic borosilicate rubber tape is 0.3-0.5mm.

[0021] The armor layer 7 is made of stainless steel fiber braided material with a wire diameter of 0.1-0.2mm, which can improve the cable's resistance to mechanical impact and compression, and protect the inner structure.

[0022] The anti-aging layer 8 includes montmorillonite composite fluororubber 81 covering the outside of the armor layer 7. The montmorillonite composite fluororubber 81 is covered with an antioxidant layer 82, which is composed of hindered phenolic antioxidant and montmorillonite particles. The composite particles of the antioxidant layer 82 are uniformly dispersed and cured into a continuous coating. The layered structure of montmorillonite can block the migration of hindered phenolic antioxidant, so as to achieve the slow release of anti-aging components. The montmorillonite composite fluororubber 81 itself has both weather resistance and mechanical strength. It works synergistically with the antioxidant layer 82 to specifically delay the thermal oxidation aging of the cable caused by high temperature and ultraviolet rays, and significantly extend the service life of the cable.

[0023] The inner layer of the gradient pore nano-aerogel in the insulation layer 5 has a higher porosity than the outer layer. The inner layer of the gradient pore nano-aerogel has a porosity of 85%, providing excellent thermal insulation, while the outer layer has a porosity of 65%, providing enhanced support.

[0024] The ceramicized silicone rubber round rod 52 has a bending radius greater than its own diameter at room temperature, which balances flexibility and high-temperature rigidity. The ceramicized silicone rubber round rod 52 is sintered into ceramic at high temperature to ensure structural stability.

[0025] The phase change capsule 53 has a phase change point of 220℃, which can buffer high temperature shocks through phase change heat absorption.

[0026] The buffer layer 6 is composed of ceramicized silicone rubber and basalt fiber, which has both room temperature elasticity and can absorb mechanical impact, as well as high temperature fire resistance.

[0027] Alumina hollow spheres 62 have a density ≤1.5g / cm³ and a temperature resistance ≥1800℃.

[0028] The array of alumina hollow spheres 62 enhances lightweight and thermal insulation. When the expanded vermiculite silicone rubber composite capsule 63 is used in adjacent gaps, it can seal the gaps through the expansion effect at temperatures above 200°C, while suppressing temperature rise through heat absorption by the paraffin phase change.

[0029] Working Principle: The innermost layer of the cable consists of conductor 1 and an insulated core. Conductor 1 is made of multi-strand silver-plated oxygen-free copper strands. The silver plating reduces oxidation and contact resistance, improving conductivity. Each conductor 1 is covered with a polyimide film with a temperature resistance of over 260℃ as an outer insulation layer. The film is wound in a semi-overlapping manner to form the insulated core, ensuring stable conductivity and electrical isolation between conductor 1 and the external structure. It maintains stable insulation performance even at 280℃, laying the foundation for the electrical safety of the cable. A shielding layer 2 is wrapped around conductor 1, using a composite structure of copper wire braided mesh and aluminum foil. The copper wire braided mesh uses oxygen-free copper wire with a diameter of 0.15 mm and a braiding density of over 90%, which improves the mechanical strength of the shielding layer 2. The aluminum foil is bonded to the copper wire braided mesh. Inside the mesh, the electromagnetic shielding effect is enhanced through metal reflection, effectively blocking external electromagnetic interference and ensuring the stability of cable signal or power transmission. An outer insulation layer 3 is wrapped around the shielding layer 2. This layer is a composite material of modified cross-linked polyethylene and nano-silica, formed by melt extrusion, with a thickness of 1.2 mm. The nano-silica particles are uniformly dispersed in the cross-linked polyethylene matrix, which can suppress the thermal motion of molecular chains at high temperatures, improving the high-temperature insulation stability and tensile strength of the outer insulation layer 3, suitable for insulation requirements under high-temperature conditions. A fire-resistant layer 4 is wrapped around the outer insulation layer 3. This layer consists of alternating layers of synthetic mica tape and ceramic borosilicate rubber tape, with a total thickness of 0.8 mm. The inner layer is ceramic borosilicate rubber tape, with a thickness of 0.4 mm, providing insulation at room temperature. The material possesses the flexibility of rubber and rapidly sintersects into a dense ceramic layer when exposed to temperatures above 300°C. The outer layer is a 0.4 mm thick synthetic mica tape coated with borosilicate resin on both sides. The layered structure of the mica tape blocks flame spread, forming a reliable fire barrier. An insulation layer 5, the core insulation component 51 for the cable, is wrapped around the fire-resistant layer 4. This includes annular insulation components 51 evenly distributed circumferentially, a central ceramicized silicone rubber rod 52, and interstitial phase change capsules 53. The insulation component 51 is filled with gradient-pore nano-aerogel, with an inner porosity of 85% and an outer porosity of 65%, and is doped with alumina ceramic fibers. The high porosity of the inner layer achieves ultimate insulation, while the low porosity of the outer layer strengthens structural support. The ceramic fibers enhance the aerogel's high-temperature crack resistance. The ceramicized silicone rubber rod... 52, with a diameter of 4 mm, exhibits good bending performance at room temperature, making it suitable for complex wiring. It is sintered into ceramic at temperatures above 300℃, providing rigid support for the heat insulation component 51. The phase change capsule 53 is a sodium nitrate-potassium nitrate eutectic salt capsule encapsulated in alumina. Through phase change heat absorption, it buffers local high-temperature impacts, controlling the temperature inside the heat insulation layer 5 below 250℃, achieving efficient heat insulation and structural stability. A buffer pad layer 6 is wrapped around the outside of the heat insulation layer 5, including a composite layer 61, an array of alumina hollow spheres 62, and a composite capsule 63 filling the gaps. The composite layer 61 is made of a composite material of ceramicized silicone rubber and basalt fiber, molded by compression molding. It has good elasticity and tensile properties at room temperature and can absorb external mechanical impacts. The alumina hollow spheres 62 are distributed in a honeycomb array with a density of 1.With a density below 5 grams per cubic centimeter and a temperature resistance above 1800℃, the hollow structure reduces heat conduction while achieving lightweight design. Composite capsule 63 is an expanded vermiculite-silicone rubber composite microcapsule containing a paraffin phase change core material. At room temperature, the silicone rubber provides elastic filling, while at temperatures above 200℃, the expanded vermiculite expands to seal the gaps, and the paraffin phase change absorbs heat, further suppressing temperature rise. Through mechanical buffering and auxiliary insulation, it effectively resists external impacts and thermal stress. An armor layer 7, woven from 304 stainless steel fibers with a wire diameter of 0.15 mm, a weaving pitch 1.8 times the bandwidth, and an overlap rate of 15%, is wrapped around the armor layer 7. This structure gives the armor layer 7 an impact resistance of over 10 kJ / m², effectively resisting external mechanical scratches and compression, and protecting the structural integrity of the inner insulation layer 5 and the buffer layer 6. An anti-aging layer 8 is wrapped around the armor layer 7, with an inner layer of montmorillonite. The cable consists of a composite fluororubber 81 layer, tightly encasing the armor layer 7. Montmorillonite enhances the weather resistance and mechanical strength of the montmorillonite composite fluororubber 81 through its layered structure. The outer layer is an antioxidant layer 82, composed of composite particles formed by the physical adsorption of powdered hindered phenolic antioxidants and montmorillonite. These particles are uniformly dispersed and cured into a continuous coating. The layered structure of montmorillonite prevents antioxidant migration, achieving slow release. Synergistically working with the inner montmorillonite composite fluororubber 81 layer, it specifically delays thermal oxidative aging, significantly extending the cable's service life. The outermost layer is the outer sheath layer 9, made of nano-reinforced EPDM rubber, extruded to a thickness of 1.5 mm. An internal graphene carbon nanotube composite thermally conductive mesh is embedded to accelerate heat transfer to the outside. The surface features spiral heat dissipation patterns, increasing the heat dissipation surface area and achieving chemical corrosion resistance, UV resistance, and efficient heat dissipation, comprehensively protecting the inner structure from environmental erosion.

[0030] The technical scope of this invention is not limited to the content described above. Those skilled in the art can make various modifications and variations to the above embodiments without departing from the technical concept of this invention, and all such modifications and variations should fall within the protection scope of this invention.

Claims

1. Multilayer composite wrap-around high temperature resistant and ageing resistant cable, characterized in that, From inside to outside in turn includes: conductor, each conductor is coated with an inner insulating layer to form an insulated cable core; shielding layer, coated outside the conductor, the shielding layer is composed of copper wire mesh and aluminum foil; outer insulating layer, coated outside the shielding layer, outer insulating layer uses modified crosslinked polyethylene and nanometer silicon dioxide composite material; fire resistance layer, coated outside the outer insulating layer; thermal insulation layer, coated outside the fire resistance layer, the thermal insulation layer is a plurality of annularly distributed thermal insulation components inside, the thermal insulation component is filled with gradient porosity nano aerogel and doped with alumina ceramic fiber, the center of the thermal insulation layer is provided with a ceramicized silicone rubber rod, the adjacent gap between the thermal insulation component and the ceramicized silicone rubber rod is filled with a phase change capsule, the phase change capsule is an alumina encapsulated sodium nitrate-potassium nitrate eutectic salt; the inner layer porosity of the gradient porosity nano aerogel of the thermal insulation layer is higher than the outer layer, the inner layer porosity of the gradient porosity nano aerogel is 85%, and the outer layer porosity is 65%; cushion layer, coated outside the thermal insulation layer, the cushion layer includes a composite layer coated on the cushion layer, the composite layer uses a composite material of ceramicized silicone rubber and basalt fiber, the composite layer is filled with alumina hollow spheres in the middle, the alumina hollow spheres are in an array, the adjacent alumina hollow sphere gap is filled with a composite capsule, and the composite capsule is an expanded vermiculite silicone rubber; armored layer, coated outside the cushion layer; anti-aging layer, coated outside the armored layer; outer sheath layer, coated outside the anti-aging layer, the outer sheath layer uses nano enhanced rubber.

2. The multi-layered composite wrap-around high temperature and ageing resistant cable according to claim 1, wherein: The fire resistance layer is composed of synthetic mica tape and ceramicized borosilicon rubber tape, the mica tape is the outer layer, and the ceramicized borosilicon rubber tape is the inner layer, the mica tape is coated with borosilicon resin on both sides, and the thickness of the ceramicized borosilicon rubber tape is 0.3-0.5 mm.

3. The multi-layered composite wrap-around high temperature and ageing resistant cable of claim 1, wherein: The armored layer is a stainless steel fiber woven material, and the diameter of the stainless steel fiber is 0.1-0.2 mm.

4. The multi-layered composite wrap-around high temperature and ageing resistant cable of claim 1, wherein: The anti-aging layer includes montmorillonite composite fluororubber coated outside the armored layer, and the montmorillonite composite fluororubber is coated with an antioxidant layer outside, the antioxidant layer is composed of hindered phenolic antioxidant and montmorillonite particles, the composite particles of the antioxidant layer are uniformly dispersed and solidified into a continuous coating.

5. The multi-layered composite wrap-around high temperature and ageing resistant cable of claim 1, wherein: The ceramicized silicone rubber rod has a bending radius greater than its own diameter at room temperature, and the ceramicized silicone rubber rod is sintered into ceramic at high temperature.

6. The multi-layered composite wrap-around high temperature and ageing resistant cable of claim 1, wherein: The phase change capsule has a phase change point of 220 DEG C.

7. The multi-layered composite wrap-around high temperature and ageing resistant cable of claim 1, wherein: The cushion layer is composed of ceramicized silicone rubber and basalt fiber.

8. The multi-layered composite wrap-around high temperature and ageing resistant cable of claim 7, wherein: The density of the alumina hollow sphere is ≤1.5 g / cm3, and the temperature resistance of the alumina hollow sphere is ≥1800 DEG C.

9. The multi-layered composite wrap-around high temperature and ageing resistant cable of claim 8, wherein: The alumina hollow sphere array improves lightweight and thermal insulation, and the expanded vermiculite silicone rubber composite capsule can seal the gap above 200 DEG C through the expansion effect when used in the adjacent gap.

Images