Lightweight ultra-low temperature resistant flexible reel cable

Abstract

The application discloses a light-weight super-low-temperature-resistant flexible drum cable and belongs to the technical field of cables.The light-weight super-low-temperature-resistant flexible drum cable comprises a cable core, an insulation layer, an inner protective layer, a reinforcing layer and an outer sheath, the cable core comprises a power line core, a grounding line core and PE foamed filling strips, braided high-strength high-modulus polyethylene fiber filaments are arranged between the cable core and the ethylene-propylene rubber insulation layer, the ethylene-propylene rubber insulation layer is braided with Kevlar fiber filaments, the Kevlar fiber filaments are coated with the inner protective layer, the inner protective layer is braided with the reinforcing layer which is formed by interweaving Kevlar fibers and basalt fibers, and the reinforcing layer is coated with the outer sheath; the inner protective layer is made of high-temperature-resistant waterproof TPU foaming material, the light-weight super-low-temperature-resistant flexible drum cable has the advantages of simple structure, excellent thermal stability, pressure resistance, wear resistance, corrosion resistance, flame resistance, aging resistance and water resistance, good bending performance, wide application range, long service life and reduced cost.

Description

Technical Field

[0001] This invention belongs to the field of cable technology, and particularly relates to a lightweight, ultra-low temperature resistant, flexible, tensile, wear-resistant, and corrosion-resistant reel cable and its preparation method. Background Technology

[0002] Reel cables are wire products specifically designed for the winding and unwinding of mobile equipment. Their core function is to achieve synchronous winding and unwinding of the cable through the rotation of the reel during the reciprocating motion of the equipment, while ensuring the stability of power transmission (or signal transmission) and the durability of the cable itself. In order to ensure that the reel cable can be used in special scenarios such as reeling machines, lifting equipment, conveyors, and drag chain systems, the reel cable must meet the following performance requirements: (1) Ensure that the core is not broken during at least 5 million reciprocating motions during use, the reel cable must have excellent bending performance under high and low temperature conditions (120℃ for metallurgical equipment or -40℃ for outdoor use in northern regions); (2) Ensure that the cable can withstand the crushing and friction of the reel, pressure roller, and track groove during movement, the reel cable must have excellent compressive strength and wear resistance; (3) Ensure that the cable can work normally in harsh environments, such as being subjected to molten steel splashes during use, having chemicals in the cable reel, pressure roller, and track groove, and being exposed to outdoor environments for a long time, the reel cable should have good flame retardant, acid and alkali resistant, weather resistant, and waterproof properties; (4) During use, if the cable is too heavy, it will cause a series of negative effects such as wear, deformation, material fatigue, and unstable operation of the equipment and the cable itself. Therefore, lightweight reel cables have better durability. Therefore, there is a need to develop a lightweight, flexurally resistant, pressure-resistant, abrasion-resistant, corrosion-resistant, high and low temperature resistant, and aging-resistant waterproof reel cable to extend the service life of the reel cable and reduce production and maintenance costs.

[0003] Invention patent CN202411418985.X discloses a lightweight flexible reel cable, including an outer sheath, a reinforcing layer, an inner sheath, a mica tape layer, a ground wire, and a main wire. The inner sheath is made of TPU, EVA, EVA-MAH, nano zinc oxide, and carbon nanotubes grafted with amino acid salt-type ionic liquids, resulting in a lightweight and high-strength reel cable that avoids adverse effects on the normal operation of equipment and the performance of the cable itself due to excessive weight. However, the introduction of a large number of pores into the inner sheath reduces its high-temperature stability, thereby reducing the cable's service life. Furthermore, the patent does not specify a particular type of TPU (polyester-type TPU has poor low-temperature resistance), which cannot guarantee its superior low-temperature flexibility.

[0004] Invention patent CN202411421997.8 discloses a flexible reel cable, comprising a core composed of an aluminum alloy conductor and an insulation layer, an inner sheath, a torsion-resistant reinforcing layer, and an outer sheath. Both the inner and outer sheaths are made of ultra-lightweight foamed TPU. The aluminum alloy conductor is made from 6101 aluminum rod, aluminum-scandium alloy, AlBC seed alloy, and lanthanum hexaboride micro / nano powder. This flexible reel cable is lightweight and has excellent bending resistance. However, the aluminum alloy material is expensive and unconventional, and its electrical performance is unstable under frequent bending and torsion conditions. Furthermore, using foamed TPU as the outer sheath leads to a decrease in the cable's high-temperature resistance, mechanical strength, and abrasion resistance, thereby reducing the cable's service life.

[0005] Invention patent CN202411617852.5 discloses a high-temperature resistant cable sheath material for preventing welding slag. The raw materials of this sheath material are: TPU, modified montmorillonite, crosslinking resin, processing aids, co-crosslinking agents, and reactive catalysts. The crosslinking resin is prepared by a reaction catalyzed by hexamethylene diisocyanate trimer and alcohol-hydroxyl-terminated silicone oil. This sheath material achieves triple high-temperature resistance modification through the high-temperature resistance properties of montmorillonite, the high-temperature resistance of silane chains, and the temperature resistance of the interpenetrating crosslinking network. This synergistic effect enables the resulting composite material to resist the temperature of the welding slag point, preventing the material surface from melting. However, the high degree of crosslinking and the introduction of a large amount of filler in this sheath material will reduce the material's flexibility and elongation, thus affecting the cable's bending performance and flexural strength. It will also increase the cable's specific gravity, which is detrimental to the movement or suspension of the cable reel, affecting the service life and application environment of the sheath material. Summary of the Invention

[0006] The main objective of this invention is to provide a lightweight, ultra-low temperature resistant flexible reel cable with a simple structure and light weight. It has excellent high temperature stability, low temperature flexibility, flexural strength, compressive strength, abrasion resistance, corrosion resistance, flame retardancy, aging resistance, and waterproof properties. It also has good bending performance and maintains good performance and a long service life even under harsh environments such as frequent dragging, coiling, and high and low temperatures.

[0007] To achieve the objectives of this invention, a lightweight, ultra-low temperature resistant flexible reel cable is provided, comprising a cable core, an insulation layer, an inner sheath, a reinforcing layer, and an outer sheath. The cable core includes a power core and a grounding core, and further includes PE foam filler strips twisted with the power core and the grounding core. The cable core is braided with high-strength, high-modulus polyethylene fiber filaments, which are then extruded with an ethylene propylene rubber insulation layer. The ethylene propylene rubber insulation layer is braided with Kevlar fiber filaments, which are then covered with the inner sheath. The inner sheath is then braided with a reinforcing layer composed of interwoven Kevlar and basalt fibers, and the reinforcing layer is covered with the outer sheath.

[0008] The inner protective layer is made of high-temperature resistant and waterproof TPU foam material;

[0009] The outer sheath is made of wear-resistant, corrosion-resistant, and highly flame-retardant TPU sheath material;

[0010] The preparation method of the high-temperature resistant and waterproof TPU foam material is as follows:

[0011] P1. Add polyether-type TPU, polyether-polyamide block copolymer and first antioxidant to a reaction vessel and mix evenly. Heat to 110±10℃, then add epoxy chain extender, heat to 185±5℃, stir and react for 3-5 min, then add 1 / 2 part by weight of amino-terminated polydimethylsiloxane, stir and react for 3-5 min, then add nucleating agent, foaming flame retardant, first lubricant and the remaining 1 / 2 part by weight of amino-terminated polydimethylsiloxane, stir and react for 5-10 min to obtain pretreated TPU material;

[0012] P2. Cool the pretreated TPU material to 90±5℃, feed it into a twin-screw extruder for extrusion granulation, and then mold the obtained TPU granules into TPU sheets;

[0013] P3. The above TPU sheet is placed in a supercritical CO2 autoclave for foaming treatment, cooled, and dried to obtain a high-temperature resistant and waterproof TPU foam material.

[0014] Furthermore, the high-temperature resistant and waterproof TPU foam material is made from the following raw materials in parts by weight: 85-95 parts of polyether-type TPU, 5-15 parts of polyether-polyamide block copolymer, 1.1-1.6 parts of epoxy chain extender, 1.2-1.8 parts of amino-terminated polydimethylsiloxane, 0.3-0.6 parts of nucleating agent, 0.5-1.5 parts of first antioxidant, 5-10 parts of foaming flame retardant, and 0.2-0.6 parts of first lubricant.

[0015] Furthermore, the epoxy chain extender is ADR-4468 or chain extender 6059;

[0016] The nucleating agent is glyceryl monostearate modified nanoclay;

[0017] The first antioxidant is one or more of antioxidant 1010, antioxidant 1098, antioxidant 1222, antioxidant 1076, and antioxidant 168;

[0018] The first lubricant is one or more of zinc stearate, butyl stearate, polydimethylsiloxane, magnesium silicate, and ethylene bis-stearamide.

[0019] Furthermore, the glyceryl monostearate modified nanoclay is prepared by melt blending glyceryl monostearate and nanoclay; or by melt blending glyceryl monostearate and nanoorganic clay.

[0020] Furthermore, the wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material is made from the following raw materials in parts by weight: 60-80 parts of polyether-type TPU, 15-25 parts of polyether-polyamide block copolymer, 5-15 parts of maleic anhydride-grafted POE, 5-15 parts of organically modified sepiolite clay, 10-20 parts of composite flame retardant, 2-5 parts of silane coupling agent, 1.2-2.5 parts of secondary antioxidant, and 0.5-1.5 parts of secondary lubricant.

[0021] Furthermore, the composite flame retardant is composed of phosphazene flame retardant SPB-100 and polyborosiloxane in a mass ratio of (2-3):1.

[0022] Furthermore, the power core comprises, from the inside out, a copper conductor, a reinforced lightweight nonwoven fabric wrapping layer, and a first TPEE insulation layer;

[0023] The grounding core consists of a tin-plated copper conductor and a second TPEE insulation layer from the inside out.

[0024] Furthermore, the high-strength, high-modulus polyethylene fiber filaments have a specification of 800-1000D and a weaving density of 30-40%;

[0025] The Kevlar fiber has a specification of 200-500D and a weaving density of 60-70%.

[0026] Furthermore, the reinforcing layer is made of Kevlar fiber and basalt fiber interwoven in a ratio of 2:1, with a weaving density of 50-60%.

[0027] The Kevlar fiber has a specification of 500-1000D;

[0028] The basalt fiber has a specification of 500-1000D.

[0029] The present invention has achieved the following beneficial effects:

[0030] The reel cable of this invention is made of a cable core made of a power core, a grounding core, and a PE foam filler strip twisted together. Then, it is made of high-strength, high-modulus polyethylene fiber filaments, ethylene propylene rubber insulation layer, Kevlar fiber filaments, inner sheath, reinforcing layer, and outer sheath arranged from the inside out. It can meet the needs of use in mobile environments such as frequent dragging and coiling rotation. It has excellent mechanical strength, bending resistance, folding resistance, abrasion resistance, corrosion resistance, and weather resistance. The reel cable can achieve a fire performance rating of B1, while also meeting the cold resistance requirements of northern cities in my country. It can withstand temperatures down to -40℃, and also has the characteristics of high temperature resistance and excellent electrical performance.

[0031] This invention incorporates reinforcing fibers between the cable core, insulation layer, inner sheath, and outer sheath, effectively improving the torsional and compressive strength of the reel cable. This protects the cable core from breakage under frequent dragging and winding conditions, ensuring the reel cable has excellent tensile strength and extending its service life. The use of PE foam filler strips helps to fix the cores during torsion, increasing bending resistance, optimizing cable structure roundness, reducing cable weight, and providing excellent low-temperature resistance and mechanical strength.

[0032] The inner sheath of this invention is made of high-temperature resistant and waterproof TPU foam material, which has a low surface density, greatly reducing the weight of the cable and ensuring stable operation of the reel cable. It also possesses excellent mechanical strength, bending resistance, folding resistance, high and low temperature resistance, shrinkage resistance, flame retardancy, and waterproofness, ensuring the dimensional stability of the reel cable during use, preventing deformation, and guaranteeing normal power transmission. The outer sheath is made of non-foamed TPU material, ensuring that the reel cable maintains excellent mechanical strength, electrical insulation, waterproofness, flame retardancy, corrosion resistance, aging resistance, thermal stability, and low-temperature flexibility even in complex mobile environments such as humidity, high metallurgical temperatures, low outdoor temperatures, and chemical corrosion, thus improving the cable's safety and service life.

[0033] The reel cable prepared by this invention is lightweight, has a smooth surface, simple structure, is easy to manufacture, and has excellent low-temperature resistance, wear resistance, torsion resistance, water resistance and corrosion resistance. It has a wide range of applications and low cost. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of a structural embodiment of the lightweight, ultra-low temperature resistant flexible reel cable of the present invention.

[0035] Attached diagram labels: 1. Copper conductor; 2. Reinforced lightweight non-woven fabric wrapping layer; 3. First TPEE insulation layer; 4. Tin-plated copper conductor; 5. Second TPEE insulation layer; 6. PE foam filler strip; 7. High-strength, high-modulus polyethylene fiber filament; 8. Ethylene propylene rubber insulation layer; 9. Kevlar fiber filament; 10. Inner sheath; 11. Reinforcing layer; 12. Outer sheath. Detailed Implementation

[0036] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] like Figure 1As shown, the present invention provides a lightweight, ultra-low temperature resistant flexible reel cable, comprising a cable core, an ethylene propylene rubber insulation layer 8, an inner sheath 10, a reinforcing layer 11, and an outer sheath 12. The cable core is externally braided with high-strength, high-modulus polyethylene fiber filaments 7, which are then extruded with the ethylene propylene rubber insulation layer 8. The ethylene propylene rubber insulation layer 8 is externally braided with Kevlar fiber filaments 9, which are then externally covered by the inner sheath 10. The inner sheath 10 is externally braided with a reinforcing layer 11 composed of interwoven Kevlar and basalt fibers, and the reinforcing layer 11 is externally covered by the outer sheath 12.

[0038] Preferably, the cable core is made of three power cores, one grounding core, and a PE foam filler strip 6 twisted together, with a twist pitch of 12 mm. This reduces the cable weight, improves the tensile and torsional strength of the cable core, ensures that the cable is less prone to core breakage during use, and extends the service life of the reel cable. Specifically, the diameter of the PE foam filler strip 6 is determined according to the specific application scenario. In this invention, the diameter of the PE foam filler strip 6 is 10 mm, and the grade is HUY05.

[0039] The power conductor core of this invention comprises, from the inside out, a copper conductor 1, a reinforcing lightweight nonwoven fabric wrapping layer 2, and a first TPEE insulation layer 3. The reinforcing lightweight nonwoven fabric wrapping layer 2 is made of aramid filament fiber nonwoven fabric, which improves the tensile strength of the copper conductor 1, prevents conductor breakage during cable movement and bending, and improves the mechanical strength, high and low temperature resistance, bending performance, and electrical properties of the power conductor core. Specifically, the aramid filament fiber nonwoven fabric of this invention has a yarn count of 50D*75D and an overlap rate of 60%.

[0040] The grounding core of the present invention includes, from the inside out, a tin-plated copper conductor 4 and a second TPEE insulation layer 5.

[0041] Specifically, the first TPEE insulation layer 3 and the second TPEE insulation layer 5 used in this invention are TPEE30C1NC010, which has good toughness and impact resistance, excellent electrical insulation, and ensures the safety of the cable core and makes it less prone to breakage.

[0042] Preferably, the high-strength, high-modulus polyethylene fiber filament 7 of the present invention is an ultra-high molecular weight polyethylene fiber filament with a specification of 800-1000D and a braiding density of 30-40%. It is lightweight, improving the cable's flexibility, tensile strength, and bending performance, preventing core breakage, and ensuring that the material fills the gaps in the UHMWPE braided layer during the extrusion process of the ethylene propylene rubber insulation layer 8, guaranteeing good bonding between the ethylene propylene rubber insulation layer 8 and the cable core, resulting in structural stability and improved overall performance of the cable, including electrical stability, bending resistance, and impact resistance. Specifically, in the embodiments of the present invention, the high-strength, high-modulus polyethylene fiber filament 7 has a specification of 800D and a braiding density of 30%.

[0043] Preferably, the EPDM rubber insulation layer 8 is made of EPDM rubber, which ensures good adhesion to the cable core and has superior elasticity, electrical insulation, high and low temperature resistance, and tear resistance, further protecting the cable core from breakage. Specifically, the EPDM rubber in this embodiment is selected from NORDEL IP 3745P EL.

[0044] Preferably, the Kevlar fiber filament 9 of the present invention has a specification of 200-500D and a braiding density of 60-70%, which further improves the tensile and bending properties of the cable of the present invention, and ensures that the material fills the gaps of the Kevlar braided layer during the extrusion process of the inner sheath 10, ensuring a good bond between the ethylene propylene rubber insulation layer 8 and the inner sheath 10, and improving the comprehensive performance of the cable in terms of electrical stability, mechanical strength, high and low temperature resistance, wear resistance, and flame retardancy. Specifically, in the embodiments of the present invention, the high-strength, high-modulus polyethylene fiber filament 7 has a specification of 400D and a braiding density of 60%.

[0045] Preferably, the inner protective layer 10 of the present invention is a high-temperature resistant and waterproof TPU foam material, which is made of the following raw materials in parts by weight: 85-95 parts of polyether-type TPU, 5-15 parts of polyether-polyamide block copolymer, 1.1-1.6 parts of epoxy chain extender, 1.2-1.8 parts of amino-terminated polydimethylsiloxane, 0.3-0.6 parts of nucleating agent, 0.5-1.5 parts of first antioxidant, 5-10 parts of foaming flame retardant, and 0.2-0.6 parts of first lubricant.

[0046] The preparation method of this high-temperature resistant and waterproof TPU foam material is as follows:

[0047] P1. Add polyether-type TPU, polyether-polyamide block copolymer and first antioxidant to a reaction vessel and mix evenly. Heat to 110±10℃, then add epoxy chain extender, heat to 185±5℃, stir at 80 r / min for 3-5 min, add 1 / 2 mass of amino-terminated polydimethylsiloxane, stir at 80 r / min for 3-5 min, then add nucleating agent, foaming flame retardant, first lubricant and the remaining 1 / 2 mass of amino-terminated polydimethylsiloxane, stir at 100 r / min for 5-10 min to obtain pretreated TPU material;

[0048] P2. Cool the pretreated TPU material to 90±5℃ and feed it into a twin-screw extruder for extrusion granulation. Set the extrusion temperature to 170-210℃. Then place the obtained TPU granules into a flat vulcanizing machine for compression molding. The temperature of the flat vulcanizing machine is 170℃, the pressure is 20MPa, and the holding time is 8min to obtain TPU sheets.

[0049] P3. The above TPU sheet was placed in a supercritical CO2 autoclave for foaming treatment. It was kept under pressure in supercritical carbon dioxide at 140℃ and 16MPa for 2 hours, then the pressure was quickly released, and it was allowed to cool naturally. It was then dried at 80℃ for 2 hours to obtain a high-temperature resistant and waterproof TPU foam material.

[0050] The high-temperature resistant and waterproof TPU foam material of this invention uses polyether-type TPU as the matrix, possessing excellent toughness and tear resistance to protect the cable core and prevent breakage or tearing. This ensures the invention exhibits good comprehensive properties such as mechanical strength, flame retardancy, low-temperature flexibility, and hydrolysis resistance. The addition of polyether-polyamide block copolymer significantly improves the mechanical strength, abrasion resistance, toughness, resilience, and electrical insulation properties of the inner sheath 10, further enhancing the cable's resistance to bending, flexural strength, and low-temperature flexibility, ensuring safe cable use. The addition of epoxy chain extender... The addition of amino-terminated polydimethylsiloxane not only improves the melt viscoelasticity and melt strength of the high-temperature resistant and waterproof TPU foam material, but also reduces the density of the high-temperature resistant and waterproof TPU foam material, making it lighter in weight. This significantly improves the mechanical strength, resilience, shrinkage resistance, waterproofness, and heat insulation of the inner sheath 10.

[0051] Preferably, the polyether-type TPU is 1185AF001 or A 92 P 4637, but it is not limited to these two. In the embodiments of the present invention, the polyether-type TPU is selected as 1185AF001.

[0052] Preferably, the polyether-polyamide block copolymers are all selected from PEBA 6011.

[0053] Preferably, the epoxy chain extender is ADR-4468 or chain extender 6059, and ADR-4468 is selected in this embodiment of the invention.

[0054] Preferably, the nucleating agent of the present invention is glyceryl monostearate modified nanoclay, that is, it is prepared by directly using glyceryl monostearate and nanoclay through melt blending; or it is prepared by using glyceryl monostearate and nanoorganic clay through melt blending.

[0055] Specifically, the nucleating agent in this embodiment of the invention is glycerol monostearate modified nano-organic clay, which is prepared as follows: first, glycerol monostearate is placed in a mixer and heated to 80-90℃ to be completely melted, and then nano-organic clay is slowly added while stirring. After stopping the addition, stirring is continued for 30 minutes, and the mixture is allowed to cool naturally (stirring needs to be continued during this process) to obtain a premix; the premix is ​​placed in a twin-screw extruder for extrusion granulation at an extruder temperature of 160-180℃, and then cooled to obtain glycerol monostearate modified nano-organic clay.

[0056] Preferably, the nano-organic clay is a hydroxyl-containing organic ammonium nano-organic montmorillonite, selected from DK2 nano-organic clay. Using the glycerol monostearate-modified nano-organic clay prepared above can further reduce the density of the high-temperature resistant waterproof TPU foam material, improve the melt strength and shrinkage resistance of the present invention, significantly improve the mechanical strength, resilience, and tear resistance of the inner sheath 10, and ensure the dimensional stability of the inner sheath 10. It is not easily deformed during repeated dragging and bending, ensuring the cable is lightweight while also extending its service life.

[0057] Preferably, the first antioxidant is one or more of antioxidant 1010, antioxidant 1098, antioxidant 1222, antioxidant 1076, and antioxidant 168. Specifically, in this embodiment of the invention, the first antioxidant is selected from antioxidant 1076 and antioxidant 168 in a mass ratio of 3:1.

[0058] Preferably, the first lubricant is one or more selected from zinc stearate, butyl stearate, polydimethylsiloxane, magnesium silicate, and ethylene bis-stearamide. Specifically, in this embodiment of the invention, the first lubricant is ethylene bis-stearamide.

[0059] Preferably, the foaming flame retardant is flame retardant RQT-CZR-3F, ​​which can give the inner protective layer 10 of the present invention high flame retardancy while not affecting the foaming effect of TPU material, thus ensuring that the inner protective layer 10 of the present invention has excellent comprehensive performance.

[0060] Preferably, the reinforcing layer 11 is made of Kevlar fiber and basalt fiber interwoven in a ratio of 2:1, with a weaving density of 50-60%, wherein the Kevlar fiber has a specification of 500-1000D and the basalt fiber has a specification of 500-1000D. Specifically, in this invention, the reinforcing layer 11 has a weaving density of 50%, and the Kevlar fiber and basalt fiber have a specification of 800D. The design of the reinforcing layer 11 improves the cable's resistance to bending and torsion, ensures the adhesion between the inner sheath 10 and the outer sheath, has a stable structure, is lightweight, and also ensures that the cable has excellent overall performance.

[0061] Preferably, the outer sheath 12 is made of wear-resistant, corrosion-resistant, and highly flame-retardant TPU sheath material, which is made of the following raw materials in parts by weight: 60-80 parts of polyether-type TPU, 15-25 parts of polyether-polyamide block copolymer, 5-15 parts of maleic anhydride-grafted POE, 5-15 parts of organically modified sepiolite clay, 10-20 parts of composite flame retardant, 2-5 parts of silane coupling agent, 1.2-2.5 parts of secondary antioxidant, and 0.5-1.5 parts of secondary lubricant. The wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material of this invention uses polyether-type TPU as the matrix, ensuring that the outer sheath 12 has good comprehensive properties such as mechanical strength, elasticity, wear resistance, low-temperature flexibility, hydrolysis resistance, tear resistance, chemical resistance, and electrical insulation. The addition of polyether-polyamide block copolymer significantly improves the mechanical strength, wear resistance, toughness, resilience, and electrical insulation properties of the outer sheath 12, extending the service life of the cable. The addition of organically modified sepiolite clay significantly improves the mechanical strength, thermal stability, flame retardancy, corrosion resistance, and wear resistance of the outer sheath 12, and also gives the outer sheath 12 good toughness, weather resistance, water resistance, and low-temperature flexibility, ensuring that the cable of this invention can be used in various extreme environments.

[0062] Preferably, the polyether-type TPU and the polyether-polyamide block copolymer are the same as those selected above. The maleic anhydride-grafted POE is selected from MA8510.

[0063] Preferably, the organically modified sepiolite clay is prepared by modifying sepiolite clay (100 mesh) with a borate coupling agent. Specifically, aminoborate-modified SB-181 is added to hot water, followed by ethanol, and stirred until homogeneous. Then, the sepiolite clay is slowly added, stirred for 30 minutes, filtered, and dried to obtain the organically modified sepiolite clay. The mass ratio of aminoborate-modified SB-181, water, and ethanol is 0.6:5:2.

[0064] Preferably, the composite flame retardant is composed of phosphazene flame retardant SPB-100 and polyborosiloxane in a mass ratio of (2-3):1. This not only ensures the flame retardancy and processability of the outer sheath 12, but also guarantees that the outer sheath 12 has excellent comprehensive properties such as waterproofness, abrasion resistance, thermal stability, low-temperature flexibility, and corrosion resistance. Specifically, in the embodiments of the present invention, the composite flame retardant is phosphazene flame retardant SPB-100 and polyborosiloxane in a mass ratio of 3:1.

[0065] Preferably, the silane coupling agent is γ-aminopropyltriethoxysilane, which enhances the bonding effect between the components and improves the overall performance of the invention, such as flame retardancy and low-temperature resistance.

[0066] Preferably, the second antioxidant is antioxidant 1010 and antioxidant 168 in a mass ratio of 1:1.

[0067] Preferably, the second lubricant is zinc stearate.

[0068] Preferably, the method for preparing the lightweight, ultra-low temperature resistant flexible reel cable of the present invention is as follows:

[0069] S1. The reinforced lightweight nonwoven tape layer 2 is wrapped around the copper conductor 1, and then the raw material of the first TPEE insulation layer 3 is extruded onto the reinforced lightweight nonwoven tape layer 2 to form a power core.

[0070] S2. The raw material of the second TPEE insulation layer 5 is extruded onto the tin-plated copper conductor 4 to form a grounding core.

[0071] S3. Twist the power core, grounding core, and PE foam filler strip 6 together to form a cable core.

[0072] S4. High-strength, high-modulus polyethylene fiber 7 is braided outside the cable core to form a UHMWPE braided layer; EPDM rubber is extruded onto the UHMWPE braided layer using an extrusion machine to form an EPDM rubber insulation layer 8.

[0073] S5. Kevlar fibers 9 are woven on the outside of the ethylene propylene rubber insulation layer 8 to form a Kevlar braided layer; then, using an extruder, high-temperature resistant and waterproof TPU foam material is extruded and coated onto the Kevlar braided layer at 170-210℃ to form an inner protective layer 10.

[0074] S6. A reinforcing layer 11, made of interwoven Kevlar and basalt fibers, is woven outside the inner protective layer 10.

[0075] S7. Weigh the raw materials of wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material according to the mass fraction, then add them to a high-speed mixer and mix them evenly at 600 r / min and 90℃. Then, convey them to a twin-screw extruder at a temperature of 170-210℃ for extrusion and granulation to obtain wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material.

[0076] S8. Using an extruder at 170-210℃, wear-resistant, corrosion-resistant, and flame-retardant TPU sheathing material is extruded and coated onto the Kevlar braided layer to form an outer sheath.

[0077] The lightweight, ultra-low temperature resistant flexible reel cable of the present invention will be described below with reference to specific embodiments.

[0078] Inner protective layer: High-temperature resistant and waterproof TPU foam material.

[0079] Example 1: The high-temperature resistant and waterproof TPU foam material is made from the following raw materials in parts by weight: 90 parts of polyether-type TPU, 10 parts of polyether-polyamide block copolymer, 1.2 parts of epoxy chain extender, 1.5 parts of amino-terminated polydimethylsiloxane, 0.4 parts of nucleating agent, 0.8 parts of first antioxidant, 8 parts of foaming flame retardant, and 0.5 parts of first lubricant.

[0080] The raw materials, raw material types, and preparation processes of this high-temperature resistant and waterproof TPU foam material are all specified in the above-described specific embodiments. Please refer to the above description for details.

[0081] Comparative Example 1: The high-temperature resistant and waterproof TPU foam material of Comparative Example 1 uses the same raw materials and preparation method as in Example 1. Specifically, it refers to Example 1, except that no polyether-polyamide block copolymer is added in Comparative Example 1, and the amount of polyether-type TPU added is 100 parts.

[0082] Comparative Example 2: The high-temperature resistant and waterproof TPU foam material of Comparative Example 2 uses the same raw materials and preparation method as in Example 1. Specifically, refer to Example 1, except that the epoxy chain extender in Comparative Example 2 is replaced with ethylene glycol amine.

[0083] Comparative Example 3: The high-temperature resistant and waterproof TPU foam material of Comparative Example 3 uses the same raw materials and preparation method as in Example 1. Specifically, refer to Example 1. The difference is that amino-terminated polydimethylsiloxane was not added in Comparative Example 3.

[0084] Comparative Example 4: The high-temperature resistant and waterproof TPU foam material of Comparative Example 4 uses the same raw materials and preparation method as in Example 1. Specifically, refer to Example 1. The difference is that in the preparation method P1 of the high-temperature resistant and waterproof TPU foam material of Comparative Example 4, the amino-terminated polydimethylsiloxane is added directly together with the nucleating agent, foaming flame retardant and the first lubricant, instead of being added separately in two parts.

[0085] Comparative Example 5: The high-temperature resistant and waterproof TPU foam material of Comparative Example 5 uses the same raw materials and preparation method as in Example 1. Specifically, refer to Example 1. The difference is that the nucleating agent of Comparative Example 5 is DK2 nano-organic clay.

[0086] Comparative Example 6: The high-temperature resistant and waterproof TPU foam material of Comparative Example 6 uses the same raw materials and preparation method as in Example 1. Specifically, refer to Example 1. The difference is that in the nucleating agent glycerol monostearate modified nano-organic clay of Comparative Example 6, the nano-organic clay used is alkyl quaternary ammonium modified high-purity montmorillonite, selected from DK1.

[0087] The high-temperature resistant and waterproof TPU foam materials prepared in Example 1 and Comparative Examples 1-6 were subjected to performance testing, as shown in Table 1 below.

[0088] Table 1 Performance test results of high temperature resistant and waterproof TPU foam material

[0089]

[0090] As can be seen from the experimental results in Table 1 above, the high-temperature resistant and waterproof TPU foam material of the present invention has a low density, while possessing high mechanical strength, resilience, shrinkage resistance, flame retardancy, high and low temperature resistance, and waterproof properties.

[0091] Outer sheath, made of wear-resistant, corrosion-resistant, and highly flame-retardant TPU sheath material:

[0092] Example 2, a wear-resistant, corrosion-resistant, and highly flame-retardant TPU sheath material, is made from the following raw materials in parts by weight: 70 parts of polyether-type TPU, 20 parts of polyether-polyamide block copolymer, 10 parts of maleic anhydride-grafted POE, 12 parts of organically modified sepiolite clay, 15 parts of composite flame retardant, 2.4 parts of silane coupling agent, 1.8 parts of secondary antioxidant, and 0.6 parts of secondary lubricant.

[0093] The raw materials, raw material types, and preparation processes of this wear-resistant, corrosion-resistant, and highly flame-retardant TPU sheath material are all specified in the above-described specific embodiments. Please refer to the above description for details.

[0094] Comparative Example 7: The wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material of Comparative Example 7 uses the same raw materials and preparation method as in Example 2, specifically referring to Example 1. The difference is that no polyether-polyamide block copolymer was added in Comparative Example 7.

[0095] Comparative Example 8: The wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material of Comparative Example 8 uses the same raw materials and preparation method as in Example 2, specifically referring to Example 1. The difference is that in this Comparative Example 8, organic bentonite (BENTONE SD-2) is used to replace organic modified sepiolite clay.

[0096] Comparative Example 9: The wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material of Comparative Example 9 uses the same raw materials and preparation method as in Example 2, specifically referring to Example 1. The difference is that the organically modified sepiolite clay in Comparative Example 9 is obtained by modifying sepiolite clay (100 mesh) with silane coupling agent KH-570.

[0097] Comparative Example 10: The wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material of Comparative Example 10 uses the same raw materials and preparation method as in Example 2, specifically referring to Example 1. The difference is that the composite flame retardant is a phosphazene flame retardant SPB-100 and zinc borate in a mass ratio of 4:1.

[0098] The wear-resistant, corrosion-resistant, and flame-retardant TPU sheathing materials prepared in Example 2 and Comparative Examples 7-10 were subjected to performance testing, as shown in Table 2 below.

[0099] Table 2 Performance test results of wear-resistant, corrosion-resistant, and flame-retardant TPU sheathing material

[0100]

[0101] As can be seen from the experimental results in Table 2 above, the wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material of the present invention has high mechanical strength, corrosion resistance, water resistance, flame retardancy, thermal stability, and low-temperature flexibility.

[0102] The lightweight, ultra-low temperature resistant flexible reel cable is manufactured using the preparation method described in the above specific embodiments. The raw materials and structure are as described in the specific embodiments, wherein the power core specification is 50mm. 2 The grounding wire core specification is 12.5mm. 2 The first TPEE insulation layer has a thickness of 6.0 mm, the second TPEE insulation layer has a thickness of 3.0 mm, the EPDM rubber insulation layer has a thickness of 4.5 mm, the inner sheath has a thickness of 5.0 mm, and the outer sheath has a thickness of 3.5 mm.

[0103] In Application Example 1, the raw materials for the high-temperature resistant waterproof TPU foam material and the wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material in the lightweight, ultra-low temperature resistant flexible reel cable are as described in Examples 1 and 2, respectively.

[0104] In Application Example 2, the raw materials for the high-temperature resistant waterproof TPU foam material and the wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material in the lightweight, ultra-low temperature resistant flexible reel cable are compared with those in Comparative Example 2 and Comparative Example 8, respectively.

[0105] In Application Example 3, the raw materials for the high-temperature resistant waterproof TPU foam material and the wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material in the lightweight, ultra-low temperature resistant flexible reel cable are compared with those in Comparative Example 5 and Comparative Example 9, respectively.

[0106] It is worth noting that the thickness difference of each layer in Application Examples 1-3 is within a reasonable range.

[0107] The performance of the lightweight, ultra-low temperature resistant flexible drum cables manufactured in Application Examples 1-3 above was tested, and the test results are shown in Table 3.

[0108] As can be seen from the test data of Application Examples 1-3, the lightweight ultra-low temperature resistant flexible drum cable of the present invention, starting from the optimization of the formulation of each cable component and the inner sheath, outer sheath, etc., makes full use of the synergistic effect between each component and component, overcomes the shortcomings described in the background art, and the product has a simple structure, is easy to manufacture, has a wide range of applications, and low cost. It also has the characteristics of excellent flame retardancy, good mechanical properties, strong corrosion resistance, wear resistance, and high and low temperature resistance.

[0109] Table 3. Cable performance test results

[0110]

[0111] The technical features of the above embodiments can be combined arbitrarily. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0112] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention.

Claims

1. A lightweight, ultra-low temperature resistant flexible reel cable, comprising a cable core, an insulation layer, an inner sheath, a reinforcing layer, and an outer sheath, wherein the cable core includes a power conductor and a grounding conductor, characterized in that, The cable core also includes PE foam filler strips twisted together with the power core and the grounding core. The cable core is braided with high-strength, high-modulus polyethylene fiber filaments. The high-strength, high-modulus polyethylene fiber filaments are extruded with an ethylene propylene rubber insulation layer. The ethylene propylene rubber insulation layer is braided with Kevlar fiber filaments. The Kevlar fiber filaments are covered with an inner sheath. The inner sheath is braided with a reinforcing layer made of interwoven Kevlar fiber and basalt fiber. The reinforcing layer is covered with an outer sheath. The inner protective layer is made of high-temperature resistant and waterproof TPU foam material; The outer sheath is made of wear-resistant, corrosion-resistant, and highly flame-retardant TPU sheath material; The preparation method of the high-temperature resistant and waterproof TPU foam material is as follows: P1. Add polyether-type TPU, polyether-polyamide block copolymer, and the first antioxidant to a reaction vessel and mix evenly. Heat to 110±10℃, then add epoxy chain extender, heat to 185±5℃, and stir for 3-5 minutes. Add 1 / 2 part by weight of amino-terminated polydimethylsiloxane, stir for 3-5 minutes, then add nucleating agent, foaming flame retardant, first lubricant, and the remaining 1 / 2 part by weight of amino-terminated polydimethylsiloxane, and stir for 5-10 minutes to obtain pretreated TPU material. P2. Cool the pretreated TPU material to 90±5℃, extrude, granulate, and mold to obtain TPU sheet. P3. Foam the above TPU sheet, cool, and dry to obtain high-temperature resistant and waterproof TPU foam material.

2. The lightweight, ultra-low temperature resistant flexible reel cable according to claim 1, characterized in that, The high-temperature resistant and waterproof TPU foam material is made from the following raw materials in parts by weight: 85-95 parts of polyether-type TPU, 5-15 parts of polyether-polyamide block copolymer, 1.1-1.6 parts of epoxy chain extender, 1.2-1.8 parts of amino-terminated polydimethylsiloxane, 0.3-0.6 parts of nucleating agent, 0.5-1.5 parts of first antioxidant, 5-10 parts of foaming flame retardant, and 0.2-0.6 parts of first lubricant.

3. The lightweight, ultra-low temperature resistant flexible reel cable according to claim 2, characterized in that, The epoxy chain extender is BASF ADR-4468 or chain extender 6059; The nucleating agent is glyceryl monostearate modified nanoclay; The first antioxidant is one or more of antioxidant 1010, antioxidant 1098, antioxidant 1222, antioxidant 1076, and antioxidant 168; The first lubricant is one or more of zinc stearate, butyl stearate, polydimethylsiloxane, magnesium silicate, and ethylene bis-stearamide.

4. The lightweight, ultra-low temperature resistant flexible reel cable according to claim 3, characterized in that, The glyceryl monostearate modified nanoclay is prepared by melt blending glyceryl monostearate, nanoclay, or nanoorganic clay.

5. The lightweight, ultra-low temperature resistant flexible reel cable according to claim 1, characterized in that, The wear-resistant, corrosion-resistant, and flame-retardant TPU sheath material is made from the following raw materials in parts by weight: 60-80 parts of polyether-type TPU, 15-25 parts of polyether-polyamide block copolymer, 5-15 parts of maleic anhydride-grafted POE, 5-15 parts of organically modified sepiolite clay, 10-20 parts of composite flame retardant, 2-5 parts of silane coupling agent, 1.2-2.5 parts of secondary antioxidant, and 0.5-1.5 parts of secondary lubricant.

6. The lightweight, ultra-low temperature resistant flexible reel cable according to claim 5, characterized in that, The composite flame retardant is composed of phosphazene flame retardant SPB-100 and polyborosiloxane in a mass ratio of (2-3):

1.

7. The lightweight, ultra-low temperature resistant flexible reel cable according to claim 1, characterized in that, The power core comprises, from the inside out, a copper conductor, a reinforced lightweight non-woven fabric wrapping layer, and a first TPEE insulation layer; The grounding core consists of a tin-plated copper conductor and a second TPEE insulation layer from the inside out.

8. The lightweight, ultra-low temperature resistant flexible reel cable according to claim 1, characterized in that, The high-strength, high-modulus polyethylene fiber filaments have a specification of 800-1000D and a weaving density of 30-40%. The Kevlar fiber has a specification of 200-500D and a weaving density of 60-70%.

9. The lightweight, ultra-low temperature resistant flexible reel cable according to claim 1, characterized in that, The reinforcing layer is made of Kevlar fiber and basalt fiber interwoven in a ratio of 2:1, with a weaving density of 50-60%. The Kevlar fiber has a specification of 500-1000D; The basalt fiber has a specification of 500-1000D.

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