High-strength composite electric power and communication pipeline and production method

Abstract

The invention discloses a high-strength composite electric power and communication pipeline and a production method thereof.The pipeline is of a multi-layer composite structure with the square outside and the round inside, high-quality ABS engineering plastic is used as a main material, a flexibilizer, a rigid supplement, an anti-aging agent, a flame retardant, a corrosion-resistant additive and other multi-element synergistic materials are used as auxiliary materials, and a high-performance composite material system is formed through scientific proportioning optimization; the material is manufactured through a one-time extrusion forming process. The pipeline has the characteristics of excellent pressure resistance, corrosion resistance, flexibility and flame retardance, can adapt to optical cables with different calibers, is flexible in combination and arrangement and convenient to construct, and is suitable for buried laying of the optical cables in the fields of Internet, mobile power and the like. The structure with the square outside and the round inside can achieve combined arrangement of multiple pipelines, free transition with original cement pipes, corrugated pipes and the like is achieved, the construction cost is remarkably reduced, performance indexes all meet or exceed the national standard, the problems that traditional pipelines are complex in construction, high in cost, poor in durability and poor in compatibility are solved, and an innovative solution is provided for modern communication network construction.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of engineering pipeline, more particularly to a high-strength composite power and communication pipeline and a production method. BACKGROUND

[0002] In the field of power and communication, various types of pipelines are important facilities for the buried laying of optical and electrical cables, such as cement pipes, corrugated pipes, and ordinary plastic pipes, which mainly serve to protect optical and electrical cables from soil pressure, moisture erosion, mechanical damage, and the like, and to ensure stable power transmission and communication signals. They are widely used in line laying projects in different scenarios such as urban roads, rural areas, and industrial parks.

[0003] Current pipelines have many problems. Traditional single-structure pipelines, such as cement pipes, are heavy but resistant to pressure, while plastic pipes are light but lack sufficient strength. Multi-layered structure pipelines often have poor interlayer adhesion due to process problems and are prone to delamination. They have high inner surface friction, making it difficult to pass cables, and poor aging resistance, flame retardation, and corrosion resistance, resulting in a short service life in complex environments. Moreover, they have poor compatibility with other pipelines, making it inconvenient to arrange and combine, and have high construction costs.

[0004] Therefore, there is an urgent need to design a high-strength composite power and communication pipeline that adopts a three-layer composite structure of outer square and inner circle, has a scientific ratio of materials in each layer, is made through one-step extrusion molding process, has high pressure resistance, aging resistance, flame retardation, and corrosion resistance, has a small inner surface friction, has good compatibility with other pipelines, and has flexible arrangement and combination. SUMMARY

[0005] The present application provides a high-strength composite power and communication pipeline and a production method to solve the problems in the prior art.

[0006] To achieve the above-mentioned purpose, the present application provides a high-strength composite power and communication pipeline and a production method, which comprises a functional layer, a reinforcing layer, and a protective layer. The reinforcing layer is wrapped outside the functional layer, and both have a hollow circular cross-section. The protective layer has a hollow circular cross-section inside and a square cross-section outside.

[0007] Preferably, the material of the functional layer comprises 97-98% ABS engineering plastic and 1-2% silicone powder.

[0008] Preferably, the material of the reinforcing layer comprises 60-70% ABS engineering plastic, 5-10% rigid supplement, and 8-17% toughening agent.

[0009] Preferably, the material of the outer protective layer comprises 70-80% ABS engineering plastic, 1-2% hindered amine anti-aging agent, 5-7% decabromodiphenyl ether flame retardant, and 2-5% chromate or PTFE micro-powder corrosion-resistant additive.

[0010] Preferably, the rigidity enhancer is glass microspheres or glass fiber; the toughening agent is ethylene-octene copolymer or SEBS.

[0011] Preferably, the specific steps of this method are as follows:

[0012] s1: Prepare the raw materials required for the inner functional layer, intermediate reinforcing layer and outer protective layer according to the proportions, and ensure that the purity and particle size of each raw material meet the production standards. Among them, ABS engineering plastics need to be screened to remove impurities.

[0013] S2 pre-crushes all solid raw materials to control the particle diameter to 2-5mm, which facilitates subsequent mixing and melting.

[0014] S3 adds 97%-98% ABS engineering plastic and 1%-2% silicone powder to a high-speed mixer and stirs at 80-90℃ for 10-15 minutes until uniformly mixed. The mixed raw material is then fed into a dryer. The dried raw material is fed into the inner extruder hopper and conveyed to various zones by a screw: the feeding zone is heated to initially soften the raw material, the compression zone further plasticizes it and removes air, and the homogenization zone completely melts and plasticizes it. The molten raw material is extruded through the inner circular die to form an initial circular inner functional layer preform.

[0015] S4 is added to the mixer at a ratio of 60%-70% ABS engineering plastic, 5%-10% rigidity additive, and 8%-17% toughening agent to ensure uniform dispersion of each component; the mixed raw material is fed into the dryer; the dried raw material is fed into the middle layer extruder and melted and plasticized through the feeding zone, compression zone, and homogenization zone; the molten intermediate reinforcing layer material is extruded through the middle layer annular die and uniformly covers the outside of the inner functional layer preform. At this time, the inner functional layer preform is not completely cooled, and the two layers of material form a preliminary bond at the interface;

[0016] S5 is added to a mixer at a ratio of 70%-80% ABS engineering plastic, 1%-2% hindered amine anti-aging agent, 5%-7% decabromodiphenyl ether flame retardant, and 2%-5% corrosion resistant additive to ensure uniform dispersion of the additives; the mixed raw materials are dried in a dryer and then fed into the outer extruder; the raw materials are melted and plasticized in the extruder at the same temperature range as the intermediate reinforcing layer; the molten outer protective layer material is extruded through the outer square die and covers the outside of the intermediate reinforcing layer to form a three-layer composite structure preform with an outer square and an inner circle.

[0017] S6 Cooling and Shaping: The billet enters the cooling water tank, first undergoes preliminary shaping in a 100-120℃ hot water section (30-40 seconds), and then enters a 20-30℃ cold water section for deep cooling (1-2 minutes) to reduce the pipe temperature to room temperature. During the cooling process, a traction machine maintains a stable pulling force to prevent pipe deformation, and the traction speed is controlled at 5-10 m / min.

[0018] After cooling, the pipes are cut to a standard length of 6m or a custom length using cutting equipment. The cut surface must be flat and burr-free. The cut pipes undergo visual inspection (no bubbles, cracks, or delamination), dimensional measurement (inner and outer diameters, wall thickness deviation ≤ ±0.2mm), and performance sampling inspection (random sampling to test compressive strength, corrosion resistance, etc.). Qualified products are put into storage.

[0019] Preferably, in step s3, the dryer dries the material at 80-90℃ for 4-6 hours to achieve a moisture content of ≤0.1%; the temperature of the feeding zone is 150-160℃; the temperature of the compression zone is 170-180℃; the temperature of the homogenization zone is 190-200℃; and the temperature of the formed blank is maintained at 180-190℃.

[0020] Preferably, in step s4, the mixer stirs at 100-110℃ for 15-20 minutes; the dryer dries at 80-90℃ for 5-7 hours, with the moisture content controlled at ≤0.1%; the temperature of the feeding zone is 160-170℃; the temperature of the compression zone is 180-190℃; the temperature of the homogenization zone is 200-210℃; and the temperature of the formed blank is maintained at 150-160℃.

[0021] Preferably, in step s5, the mixer stirs at 90-100℃ for 12-18 minutes, and the dryer dries at 80-90℃ for 4-6 hours, with a moisture content ≤0.1%; the temperature of the feeding zone is 160-170℃; the temperature of the compression zone is 180-190℃; and the temperature of the homogenization zone is 200-210℃.

[0022] Compared with the prior art, the present invention has the following advantages:

[0023] The structural design offers significant advantages: the innovative three-layer composite structure with an outer square and an inner circle. The square outer layer allows for a more stable and orderly arrangement of multiple pipes, saving space and improving the flexibility of construction layout; the circular inner layer is adapted to the contact area of ​​optical cables, and combined with the lubrication characteristics of the inner functional layer, it significantly reduces cable pulling resistance and improves construction efficiency. The three-layer structure works in synergy, resulting in superior overall mechanical performance and stronger resistance to deformation compared to traditional single structures.

[0024] Comprehensive improvement in material performance: The modified ABS material in the inner functional layer contains silicone powder, significantly reducing the coefficient of friction on the inner wall and protecting the optical cable from damage during insertion. The ABS matrix in the intermediate reinforcing layer, in synergy with rigidity enhancers and toughening agents, enables the pipe's compressive strength to be ≥400kN / m. 2 The impact resistance is significantly improved, enabling it to cope with complex terrain and high-pressure environments. Various additives in the outer protective layer give the pipeline an acid and alkali corrosion resistance level of ≥7 and make it stable in environments with pH 2-12; anti-aging agents extend its service life to more than 50 years; flame retardants ensure an oxygen index of ≥28%, improving safety.

[0025] The production process is highly efficient and advanced: a single-stage extrusion molding process achieves simultaneous molding of all layers, reducing production steps, shortening the cycle time, and lowering costs. Furthermore, each layer bonds at the molecular level during molding, preventing delamination and ensuring the integrity and stability of the pipe. Compared to multiple molding processes, this results in more reliable product quality.

[0026] Convenient and economical construction application: The pipeline combination and arrangement are flexible, and it can be connected with cement pipes, corrugated pipes, etc. through special joints, which has good compatibility and reduces construction transition costs. Standardized accessories enable rapid installation and shorten the construction cycle. In scenarios such as road crossings and complex terrain, no complicated protective measures are required, reducing project costs by more than 30% and resulting in low total life cycle costs. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0028] Fig. 1 The attached figure is a flowchart of the production method of the present invention.

[0029] Fig. 2 The attached figure is a schematic diagram of the structure of the present invention. Detailed Implementation

[0030] To facilitate understanding by those skilled in the art, various embodiments of this patent will be described below with reference to text and accompanying drawings. For clarity, many practical details will be explained in the following description. However, it should be understood that these practical details in the specification should not be used to limit this patent. That is, in some embodiments of this patent, these practical details are not essential. Furthermore, for ease of understanding, some conventional structures and components will be illustrated in the drawings in a simple schematic manner.

[0031] Please see the appendix Figs. 1-2 This invention discloses a high-strength composite power and communication conduit, comprising: an inner functional layer 3 made of modified ABS material, containing 97%-98% ABS engineering plastic and 1%-2% silicone powder; an intermediate reinforcing layer 2 being a mixture of 60%-70% ABS engineering plastic, 5%-10% rigidity reinforcement (glass microspheres or glass fiber), and 8%-17% toughening agent (ethylene-octene copolymer or SEBS); and an outer protective layer 1 composed of 70%-80% ABS engineering plastic, 1%-2% hindered amine anti-aging agent, 5%-7% decabromodiphenyl ether flame retardant, and 2%-5% chromate or PTFE micro powder corrosion resistant additive.

[0032] The specific dimensions are as follows: For 92mm diameter pipes, the inner functional layer has an inner diameter of 80mm and a thickness of 1.5mm; the intermediate reinforcing layer is 3mm thick; and the outer protective layer has an outer side length of 92mm and a thickness of 1.5mm. For 110mm diameter pipes, the inner functional layer has an inner diameter of 95mm and a thickness of 2mm; the intermediate reinforcing layer is 3.5mm thick; and the outer protective layer has an outer side length of 110mm and a thickness of 2mm. The standard pipe length is 6m.

[0033] Specifically, the raw materials for the inner functional layer 3 are mixed and dried for 4-6 hours (80-90℃), then extruded into a circular preform through an inner layer extruder (feeding zone 150-160℃, compression zone 170-180℃, homogenization zone 190-200℃). The raw materials for the intermediate reinforcing layer 2 are dried and fed into a middle layer extruder (feeding zone 160-170℃, compression zone 180-190℃, homogenization zone 200-210℃), melted, and then extruded through the annular gap to coat the inner functional layer. The raw materials for the outer protective layer 1 are dried and added to the outer layer extruder, melted, and then extruded through a square die to coat the intermediate reinforcing layer. All three layers are simultaneously cooled and shaped, then traction-cut.

[0034] Specifically, the lubrication of the inner functional layer 3 reduces friction in the optical cable; the materials of the intermediate reinforcing layer 2 synergistically enhance the overall strength and toughness, resisting external pressure and impact; the additives in the outer protective layer 1 provide aging resistance, flame retardancy, and corrosion resistance, and the square structure facilitates assembly and support. The three layers are tightly bonded together to form a high-performance composite pipe.

[0035] Application: Used for underground laying of power and communication optical cables. They can be arranged in combination as needed and connected with special connectors. They can be laid in stacks when crossing high-voltage areas such as roads. No additional anti-corrosion treatment is required in acidic or alkaline environments.

[0036] Specifically, the inner functional layer is composed of 97%-98% ABS engineering plastic and 1%-2% silicone powder, with the silicone powder reducing the material's coefficient of friction.

[0037] The specific dimensions are: thickness 1.5-2mm, inner diameter of 80mm for 92mm specification pipes, and inner diameter of 95mm for 110mm specification pipes, to ensure that the optical cable can be smoothly inserted.

[0038] Specifically, ABS engineering plastic and silicone powder are placed in a mixer in a certain proportion and mixed at 80-90℃ for 10-15 minutes, then dried for 4-6 hours (moisture content ≤0.1%). The mixture is then fed into an inner layer extruder, with the temperature of each zone controlled, and extruded through a die to form a circular inner functional layer preform, preparing for subsequent lamination.

[0039] The silicone powder is uniformly dispersed in the ABS matrix to form a lubricating surface layer. When the optical cable is inserted, it reduces the friction with the inner wall, reduces the difficulty of construction, and protects the optical cable insulation layer from wear.

[0040] Usage: Directly contacts the optical cable. During the laying of the optical cable, the optical cable can be easily passed through the inner functional layer using a traction device. It is suitable for laying optical cables of different diameters.

[0041] Specifically, the intermediate reinforcing layer 2 is made of 60%-70% ABS engineering plastic as the matrix, with 5%-10% rigidity supplement (glass microspheres with a particle size of 5-20μm and glass fiber length of 3-5mm) and 8%-17% toughening agent (ethylene-octene copolymer or SEBS) added. The rigidity supplement improves the compressive strength, and the toughening agent enhances the impact resistance.

[0042] The specific dimensions are: thickness 3-4mm, 3mm for 92mm pipes, and 3.5mm for 110mm pipes, providing the main structural support for the pipes.

[0043] Specifically, the raw materials are mixed in proportion, dried, and then fed into the middle-layer extruder. The extruder temperature is controlled, and after the raw materials are melted and plasticized, they are extruded through the annular gap of the middle-layer die, evenly coating the outer side of the inner functional layer. At this point, the inner functional layer is not completely cooled, and the molecules of the two layers diffuse into each other at the interface, forming a strong bond.

[0044] Rigid reinforcing agents act as a skeleton in the material, dispersing external pressure and improving the pipeline's compressive strength; toughening agents absorb energy when the material is impacted, preventing crack propagation and enhancing impact resistance. Together, these two components make the intermediate reinforcing layer the core of the pipeline's strength. As a strength support layer for the pipeline, it resists deformation and damage through its own strength when the pipeline is subjected to external forces such as soil pressure and vehicle loads, ensuring the safety of the inner functional layers and the fiber optic cables.

[0045] Specifically, the outer protective layer 1 is composed of 70%-80% ABS engineering plastic, 1%-2% hindered amine anti-aging agent, 5%-7% decabromodiphenyl ether flame retardant, and 2%-5% corrosion resistant additive (chromate or PTFE micro powder). The anti-aging agent delays material aging, the flame retardant prevents combustion, and the corrosion resistant additive resists chemical corrosion.

[0046] The specific dimensions are as follows: thickness 1.5-2mm, outer side length of 92mm for 92mm specification pipe, outer side length of 110mm for 110mm specification pipe, and square structure for easy combination and connection with other pipes.

[0047] Specifically, the raw materials are mixed in proportion, dried, and then added to the outer extruder, with the temperature controlled to match that of the intermediate reinforcing layer. After the raw materials are melted and plasticized, they are extruded through the outer square die, covering the outside of the intermediate reinforcing layer. The three layers are cooled simultaneously within the die, shaping into an outer square and inner round structure. Anti-aging agents absorb ultraviolet rays, reducing material oxidation and degradation; flame retardants form a flame-retardant barrier at high temperatures, inhibiting combustion; corrosion-resistant additives form a protective film on the surface, preventing the penetration of corrosive media such as acids and alkalis. The square outer layer increases the contact area with other pipes or soil, improving overall stability.

[0048] As the outer protective layer of the pipeline, it comes into direct contact with the external environment, resisting corrosive substances in the soil and ultraviolet radiation when buried underground. The square structure allows multiple pipes to be arranged closely, saving space, and can be connected to cement pipes, corrugated pipes, etc. through transition joints to achieve a smooth transition between different pipeline systems.

[0049] This application uses a uniquely designed extruder with a triple extrusion nozzle. The triple extrusion nozzle adopts a concentric nested structure, consisting of an inner circular die, a middle annular die, and an outer square die, from the inside out. The coaxiality deviation of the three is controlled within a very small range. They are fixed on the same frame by flanges with a spacing of 5-10mm.

[0050] Inner circular die: The inner diameter of the die is matched with the inner functional layer blank, and an expansion angle is provided at the outlet to facilitate smooth extrusion of the melt. A temperature sensor interface is provided on the outer wall to monitor the die temperature in real time.

[0051] Middle layer annular die: The width of the annular channel is adapted to the thickness of the middle reinforcing layer. The inner wall and the outer wall of the inner layer die form an annular gap. The gap error is controlled within a very small range. A spiral guide groove is set inside the die to make the melt evenly distributed.

[0052] Outer square die: The inner cavity is square with rounded corners. A conical guide section is provided at the entrance to ensure that the melt fills the cavity smoothly. Heating coils and cooling water channels are installed on the outside of the die to precisely control the temperature.

[0053] Each of the three dies is connected to an independent melt distribution channel. The inner surface of the channel is polished to reduce melt flow resistance. Each channel inlet is equipped with a pressure sensor to adjust the extrusion pressure in real time, ensuring that the three layers of melt are synchronously coated and formed.

[0054] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0055] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A high strength composite power and communication conduit, characterized in that, It comprises: The functional layer (3) enhances the layer (2) and the protective layer (1), the enhancement layer (2) is wrapped outside the functional layer (3), the cross section of both is hollow circular, the cross section of the protective layer (1) is hollow circular inside and square outside.

2. The high strength composite power and communication conduit of claim 1, wherein, The material of the functional layer (3) contains 97%-98% ABS engineering plastic and 1%-2% silicone powder.

3. The high strength composite power and communication conduit of claim 1, wherein, The material of the enhancement layer (2) contains 60%-70% ABS engineering plastic, 5%-10% rigid supplement and 8%-17% toughening agent.

4. The high strength composite power and communication conduit of claim 1, wherein, The material of the outer protective layer (1) contains 70%-80% ABS engineering plastic, 1%-2% hindered amine anti-aging agent, 5%-7% decabromodiphenyl ether flame retardant and 2%-5% chrome salt or PTFE micro powder corrosion resistant additive.

5. The high strength composite power and communication conduit of claim 3, wherein, The rigid supplement is glass microbeads or glass fiber; the toughening agent is ethylene-octene copolymer or SEBS.

6. The method for producing high-strength composite power and communication pipelines according to claim 1, characterized in that, It comprises the following steps: s1: prepare the required raw materials for the inner functional layer (3), the middle enhancement layer (2) and the outer protective layer (1) respectively in proportion, ensure that the purity and particle size of each raw material meet the production standard, and the ABS engineering plastic needs to be screened to remove impurities; s2: pre-pulverize all solid raw materials to control the particle diameter to 2-5mm for subsequent mixing and melting; s3: add 97%-98% ABS engineering plastic and 1%-2% silicone powder into a high-speed mixer, stir at 80-90℃ for 10-15 minutes, mix uniformly; send the mixed raw materials into a dryer; after drying, put the raw materials into the inner layer extruder hopper, convey through the screw to each area: heating in the feeding area to make the raw materials preliminarily soften, further plasticize and exclude air in the compression area, completely melt and plasticize in the homogenizing area; the melted raw materials are extruded through the inner layer circular die to form the initial circular inner functional layer blank; s4: add 60%-70% ABS engineering plastic, 5%-10% rigid supplement and 8%-17% toughening agent into the mixer in proportion to ensure uniform dispersion of each component; send the mixed raw materials into a dryer; after drying, put the raw materials into the middle layer extruder, melt and plasticize through the feeding area, compression area and homogenizing area; the melted middle enhancement layer material is extruded through the middle layer ring die to uniformly coat the outside of the inner functional layer blank, and at this time the inner functional layer blank is not completely cooled, and the two layers form initial combination at the interface; s5: add 70%-80% ABS engineering plastic, 1%-2% hindered amine anti-aging agent, 5%-7% decabromodiphenyl ether flame retardant and 2%-5% corrosion resistant additive into the mixer in proportion to ensure uniform dispersion of the additives; after drying by the dryer, put the mixed raw materials into the outer layer extruder; the raw materials are melted and plasticized in the extruder at the same temperature interval as the middle enhancement layer; the melted outer protective layer material is extruded through the outer layer square die to coat the outside of the middle enhancement layer to form a three-layer composite structure blank with outer square and inner circle; s6 cooling and shaping, the pipe is cooled in a water tank, first in a hot water section at 100-120℃ for preliminary shaping (30-40 seconds), then in a cold water section at 20-30℃ for deep cooling (1-2 minutes), so that the pipe temperature is reduced to room temperature; during the cooling process, the pipe is kept stable tension by a traction machine to avoid pipe deformation, and the traction speed is controlled at 5-10 m / min; s7 the cooled pipe is cut by a cutting device according to 6m standard length or customized length, the cutting surface needs to be smooth without burrs; the cut pipe is subjected to appearance inspection (no bubbles, cracks, delamination), size measurement (inner and outer diameter, wall thickness deviation ≤±0.2mm) and performance sampling test (random sampling test for compressive strength, corrosion resistance, etc.), and the qualified products are put into storage.

7. The method for producing high-strength composite power and communication pipelines according to claim 6, characterized in that, In the step s3, the dryer is used to dry at 80-90℃ for 4-6 hours, so that the moisture content is ≤0.1%; the feeding zone temperature is 150-160℃; the compression zone temperature is 170-180℃; and the homogenization zone temperature is 190-200℃; and the pipe temperature after shaping is kept at 180-190℃.

8. The method for producing high-strength composite power and communication pipelines according to claim 6, characterized in that, In the step s4, the mixer is used to stir at 100-110℃ for 15-20 minutes; the dryer is used to dry at 80-90℃ for 5-7 hours, and the moisture content is controlled at ≤0.1%; the feeding zone temperature is 160-170℃; the compression zone temperature is 180-190℃; the homogenization zone temperature is 200-210℃; and the pipe temperature after shaping is kept at 150-160℃.

9. The method for producing high-strength composite power and communication pipelines according to claim 6, characterized in that, In the step s5, the mixer is used to stir at 90-100℃ for 12-18 minutes, and the dryer is used to dry at 80-90℃ for 4-6 hours, and the moisture content is ≤0.1%; the feeding zone temperature is 160-170℃; the compression zone temperature is 180-190℃; and the homogenization zone temperature is 200-210℃.

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