A long-life wear-resistant cable and a method for manufacturing the same

Abstract

The application relates to the technical field of cables, and discloses a long-service-life wear-resistant cable and a preparation method thereof.The long-service-life wear-resistant cable comprises a conductor, an insulation layer and a sheath layer arranged in sequence from inside to outside, and the preparation method of the sheath layer comprises the following steps: S1, mixing styrene-butadiene rubber and butadiene nitrile rubber, then adding 60wt% carbon black N110 and 50wt% aromatic oil, adding 40wt% carbon black N110 after mixing, and obtaining mixed glue A after one-time closed mixing; S2, mixing the mixed glue A with carbon black N330 and 50wt% aromatic oil, and obtaining mixed glue B after two-time closed mixing; and S3, mixing the mixed glue B with the remaining sheath layer raw materials, three-time closed mixing, extruding outside the insulation layer, and obtaining the sheath layer.Through the technical scheme, the problem of insufficient wear resistance of the cable in the related art is solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cable, in particular, it relates to a kind of high life wear-resistant cable and preparation method thereof. BACKGROUND

[0002] In the field of industrial production, energy transmission, infrastructure construction, cable as the core carrier of power and signal transmission, its operating environment is often complex and harsh, for example, mine cable needs to resist ore impact and dust wear, outdoor laying cable needs to bear ultraviolet, temperature alternation and external force collision for a long time.In these scenarios, the sheath layer of cable is directly in contact with the outside world, and insufficient wear resistance will lead to rapid damage of the sheath, and insufficient service life will increase the frequency of replacement and maintenance cost, therefore, the wear resistance and service life of cable become the key indicators to determine its reliability.

[0003] In the prior art, in order to improve the wear resistance of the sheath layer of cable, wear-resistant fillers such as carbon black are often added to the raw materials of the sheath layer of cable, but the addition of carbon black will significantly increase the viscosity of the rubber system, reduce the fluidity and plasticity of the material, and if the carbon black cannot be uniformly dispersed in the mixing process, local stress concentration points will be formed, which not only cannot effectively play the role of reinforcement, but also weaken the wear resistance, but when the degree of mixing is too large, the degradation of macromolecular chains of the matrix material will be further intensified, which will exceed the effect of increasing the dispersion degree of carbon black, and then lead to the damage of the wear resistance of the material.

[0004] Therefore, it is necessary to develop a wear-resistant cable with high service life. SUMMARY

[0005] The present application provides a kind of high life wear-resistant cable and preparation method thereof, solve the problem of insufficient wear resistance of cable in the related art.

[0006] The technical scheme of the present application is as follows: the present application provides a kind of high life wear-resistant cable, including conductor, insulating layer and sheath layer arranged from inside to outside, the sheath layer includes the following weight parts component raw materials: styrene-butadiene rubber 100 parts, nitrile rubber 10~15 parts, carbon black N110 30~40 parts, carbon black N330 15~20 parts, plasticizer 2~4 parts, vulcanizing agent 2~4 parts, accelerator 2~3 parts, aromatic oil 3~5 parts, antioxidant 1~3 parts, the preparation method of the sheath layer includes the following steps:

[0007] S1, after mixing styrene-butadiene rubber and nitrile rubber, add 60wt% carbon black N110 and 50wt% aromatic oil, after mixing, add 40wt% carbon black N110, once mixing to obtain mixed rubber A;

[0008] S2, mix the mixed rubber A with carbon black N330 and 50wt% aromatic oil, after twice mixing, obtain mixed rubber B;

[0009] S3. Mix the mixed adhesive B with the remaining sheath layer raw materials, and after three intensive mixing processes, extrude it onto the outside of the insulation layer to obtain the sheath layer;

[0010] The first internal mixing is performed at a speed of 42-48 r / min for 5-6 min, the second internal mixing is performed at a speed of 60-70 r / min for 3.5-4 min, and the third internal mixing is performed at a speed of 50-55 r / min for 2-3 min.

[0011] The rotation speed of a single kneading cycle is 42~48 r / min, for example, 42 r / min, 43 r / min, 44 r / min, 45 r / min, 46 r / min, 47 r / min, or 48 r / min, preferably 45 r / min; the time is 5~6 min, for example, 5 min, 5.2 min, 5.5 min, 5.8 min, or 6 min, preferably 6 min.

[0012] The rotation speed of the secondary internal mixing is 60~70 r / min, for example, it can be 60 r / min, 61 r / min, 62 r / min, 63 r / min, 64 r / min, 65 r / min, 66 r / min, 67 r / min, 68 r / min, 69 r / min, or 70 r / min, preferably 70 r / min; the time is 3.5~4 min, for example, it can be 3.5 min, 3.8 min, or 4 min, preferably 4 min.

[0013] The rotation speed for the three internal kneading processes is 50~55 r / min, for example, 50 r / min, 51 r / min, 52 r / min, 53 r / min, 54 r / min, or 55 r / min, preferably 55 r / min; the time is 2~3 min, for example, 2 min, 2.2 min, 2.5 min, 2.8 min, or 3 min, preferably 2 min.

[0014] As a further technical solution, the conductor is made of copper.

[0015] The conductor material of the high-life wear-resistant cable of this invention is copper. Copper has high tensile strength and ductility, and is not easy to break when the cable is frequently bent, dragged or subjected to external friction and impact. In high-friction environments, the wear-resistant cable is prone to heat accumulation due to friction between the sheath layer and the outside world and the heat generated by the conductor itself. The thermal conductivity of copper is much higher than that of other common conductor materials such as aluminum, which can quickly conduct heat from the inside to the sheath layer and dissipate it, avoiding local high temperature that accelerates the aging of the rubber in the sheath layer and ensuring the long-term stability of the wear resistance performance of the sheath layer.

[0016] As a further technical solution, the material of the insulating layer is styrene-butadiene rubber.

[0017] The insulation material of the high-life wear-resistant cable of this invention is styrene-butadiene rubber (SBR). The SBR insulation has a similar chemical structure to the main material of the sheath layer, and the molecular chains of the two have a strong affinity, which can form a tight interfacial bond. This compatibility can reduce the relative sliding between the insulation layer and the sheath layer when the cable is repeatedly rubbed and bent, and avoid the wear of the sheath layer caused by interlayer friction. At the same time, when the sheath layer is subjected to external impact or friction stress, the SBR insulation layer can share the stress through elastic deformation, reduce the risk of damage caused by local stress concentration in the sheath layer, and indirectly extend the wear-resistant life of the sheath layer.

[0018] As a further technical solution, the plasticizer includes one or more of dioctyl phthalate, dibutyl phthalate, and diisodecyl phthalate, preferably dioctyl phthalate.

[0019] The invention adds a plasticizer to the sheath layer of the high-life wear-resistant cable. The plasticizer reduces the intermolecular forces by inserting between the rubber molecular chains, significantly improving the processing fluidity of the styrene-butadiene rubber and nitrile rubber blend system. Its lubricating effect can reduce the shear resistance during the mixing process, reduce the breakage of rubber molecular chains caused by excessive shearing, protect the integrity of the matrix structure, and lay the foundation for the formation of a stable cross-linked network during subsequent vulcanization.

[0020] As a further technical solution, the vulcanizing agent includes one or more of sulfur, benzoyl peroxide, and dicumyl peroxide, preferably sulfur.

[0021] The present invention adds a vulcanizing agent, preferably sulfur, to the sheath layer of the high-life wear-resistant cable. Sulfur can cross-link with the double bonds of the rubber molecular chain to form stable sulfur bridge bonds, which transforms the linear rubber molecules into a three-dimensional network structure, ensuring that the sheath layer maintains its structural integrity during long-term friction.

[0022] As a further technical solution, the accelerator includes one or more of accelerator DM, accelerator TMTD, and accelerator NS, preferably accelerator NS.

[0023] The present invention adds an accelerator to the sheath layer of the high-life wear-resistant cable. The addition of the accelerator can accelerate the reaction rate of the vulcanizing agent, shorten the vulcanization time, ensure a more complete and uniform cross-linking reaction, ensure the consistency of the sheath layer material, and reduce wear-resistant weak points caused by insufficient local cross-linking.

[0024] As a further technical solution, the antioxidant includes one or more of antioxidant 2246, antioxidant 4010NA, and antioxidant MB, preferably antioxidant 4010NA.

[0025] The present invention adds an antioxidant to the sheath layer of the high-life wear-resistant cable. The antioxidant can capture free radicals generated by the rubber molecular chain due to heat and oxygen, interrupt the oxidation chain reaction, delay the breakage of the styrene-butadiene rubber and nitrile rubber molecular chains, avoid the performance degradation of the sheath layer due to heat and oxygen aging, and ensure that the material can still maintain sufficient mechanical strength to resist wear under friction environment. At the same time, the addition of antioxidant can significantly improve the weather resistance of the sheath layer, effectively delay the surface cracking and powdering of the material in outdoor environments with changes in light and humidity, and extend the service life of the cable.

[0026] As a further technical solution, the carbon black N110 is pretreated carbon black N110. The preparation method of the pretreated carbon black N110 includes the following steps: dispersing piperazine benzoic acid compound in a solvent, adding carbon black N110, mixing and drying to obtain pretreated carbon black N110.

[0027] The carbon black N110 used in the high-life wear-resistant cable sheath layer of this invention is pretreated before use. The carboxyl groups contained in the piperazine benzoic acid compound can form hydrogen bonds with the hydroxyl groups on the surface of carbon black, thereby introducing benzene rings and piperazine groups on the surface of carbon black. This reduces the secondary agglomeration of high-structure carbon black N110 during the mixing process, allowing the carbon black to bear stress more evenly and improving the mechanical properties of the cable.

[0028] As a further technical solution, in the pretreatment of carbon black N110, the mass ratio of carbon black N110 to the piperazine benzoic acid compound is 50:4~5.

[0029] As a further technical solution, the solvent is anhydrous ethanol.

[0030] As a further technical solution, in the pretreatment of carbon black N110, the mass ratio of the solvent to the carbon black N110 is 4~5:1, for example, it can be 4:1, 4.1:1, 4.2:1, 4.3:1, 4.4:1, 4.5:1, 4.6:1, 4.7:1, 4.8:1, 4.9:1, 5.0:1, preferably 4:1.

[0031] As a further technical solution, the mixing time is 3 to 5 hours, for example, it can be 3 hours, 3.2 hours, 3.5 hours, 4 hours, 4.2 hours, 4.5 hours, 4.8 hours, or 5 hours, preferably 4 hours.

[0032] As a further technical solution, the piperazine benzoic acid compound includes one or both of 4-(4-methylpiperazine)benzoic acid and 4-(piperazine-1-yl)benzoic acid.

[0033] The present invention also proposes a method for preparing a high-life wear-resistant cable, which includes the following steps: after sequentially setting an insulation layer and a sheath layer on the outside of the conductor, vulcanization is performed to obtain a high-life wear-resistant cable.

[0034] The working principle and beneficial effects of this invention are as follows:

[0035] In the sheath layer of the high-life, wear-resistant cable of this invention, the carbon black is composed of carbon black N110 and carbon black N330. The addition of carbon black is combined with an intensive mixing process, effectively promoting carbon black dispersion while avoiding over-mixing, thereby improving the cable's wear resistance. In existing technologies, wear-resistant filler carbon black is often added to the sheath layer raw materials to improve cable wear resistance, but insufficient carbon black dispersion can occur during the intensive mixing process. In the preparation process of the sheath layer of the high-life, wear-resistant cable of this invention, carbon black N110 and carbon black N330 are added stepwise, synergistically in a three-stage mixing process. The low speed and long mixing time of the first mixing, combined with the high-structure carbon black N110, helps the matrix material enter the pores of the carbon black, enhancing the bonding between the filler and the matrix material. The second mixing has a higher speed and a moderate time, and with the addition of carbon black N330, the high shear force from the higher speed ensures sufficient dispersion of the matrix material and carbon black. At the same time, the moderate mixing time prevents over-mixing. The third mixing has a moderate speed and the shortest time, adding the remaining raw materials. At a moderate speed, the vulcanizing agent, accelerator, and other additives are uniformly fused with the mixed rubber, avoiding local overheating and over-mixing caused by excessive speed, and ensuring that the binding sites of carbon black and rubber molecular chains are fully preserved. Combining the method of adding carbon black with the mixing process improves the wear resistance of the cable. Detailed Implementation

[0036] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0037] In the following examples and comparative examples:

[0038] Styrene-butadiene rubber: Model 1502;

[0039] Nitrile rubber: Carboxyl-terminated nitrile rubber, model CN-15, purchased from Tianyuan Aviation Materials (Yingkou) Technology Co., Ltd.

[0040] Example 1

[0041] A method for preparing a long-life, wear-resistant cable includes the following steps:

[0042] S1. Styrene-butadiene rubber is extruded onto the outside of a copper conductor to obtain a semi-finished product;

[0043] S2. Mix 100 parts of styrene-butadiene rubber and 10 parts of acrylonitrile rubber, then add 18 parts of carbon black N110 and 1.5 parts of aromatic oil. After mixing for 1 minute, add 12 parts of carbon black N110 and mix at 45 r / min for 6 minutes to obtain mixed rubber A.

[0044] S3. Mix the mixed rubber A with 15 parts of carbon black N330 and 1.5 parts of aromatic oil, and then mix at 70 r / min for 4 min to obtain mixed rubber B;

[0045] S4. Mix the mixed adhesive B with 2 parts dioctyl phthalate, 2 parts sulfur, 2 parts accelerator NS and 1 part antioxidant 4010NA. After mixing at 55 r / min for 2 min, extrude the mixture onto the outside of the semi-finished product to obtain the sheath layer. After vulcanization, a high-life wear-resistant cable is obtained.

[0046] Example 2

[0047] A method for preparing a long-life, wear-resistant cable includes the following steps:

[0048] S1. Styrene-butadiene rubber is extruded onto the outside of a copper conductor to obtain a semi-finished product;

[0049] S2. Mix 100 parts of styrene-butadiene rubber and 12 parts of acrylonitrile rubber, then add 21 parts of carbon black N110 and 2 parts of aromatic oil. After mixing for 1 minute, add 14 parts of carbon black N110 and mix at 45 r / min for 6 minutes to obtain mixed rubber A.

[0050] S3. Mix mixed rubber A with 18 parts carbon black N330 and 2 parts aromatic oil, and then mix at 70 r / min for 4 min to obtain mixed rubber B.

[0051] S4. Mix the mixed adhesive B with 3 parts dioctyl phthalate, 3 parts sulfur, 2.5 parts accelerator NS, and 2 parts antioxidant 4010NA. Mix at 55 r / min for 2 min and extrude onto the outside of the semi-finished product to obtain the sheath layer. After vulcanization, a high-life wear-resistant cable is obtained.

[0052] Example 3

[0053] A method for preparing a long-life, wear-resistant cable includes the following steps:

[0054] S1. Styrene-butadiene rubber is extruded onto the outside of a copper conductor to obtain a semi-finished product;

[0055] S2. Mix 100 parts of styrene-butadiene rubber and 15 parts of acrylonitrile rubber, then add 24 parts of carbon black N110 and 2.5 parts of aromatic oil. After mixing for 1 minute, add 16 parts of carbon black N110 and mix at 45 r / min for 6 minutes to obtain mixed rubber A.

[0056] S3. Mix the mixed rubber A with 20 parts of carbon black N330 and 2.5 parts of aromatic oil, and then mix at 70 r / min for 4 min to obtain mixed rubber B;

[0057] S4. Mix the mixed adhesive B with 4 parts dioctyl phthalate, 4 parts sulfur, 3 parts accelerator NS, and 3 parts antioxidant 4010NA. Mix at 55 r / min for 2 min and extrude onto the outside of the semi-finished product to obtain the sheath layer. After vulcanization, a high-life wear-resistant cable is obtained.

[0058] Example 4

[0059] Compared with Example 2, Example 4 differs in that carbon black N110 is replaced with an equal amount of pretreated carbon black N110 prepared by the following preparation method. The preparation method of pretreated carbon black N110 includes the following steps: dispersing 4 parts of 4-(4-methylpiperazine)benzoic acid in 200 parts of anhydrous ethanol, adding 50 parts of carbon black N110, mixing for 4 hours and then drying to obtain pretreated carbon black N110.

[0060] Example 5

[0061] The difference between Example 5 and Example 4 is that 4-(4-methylpiperazine)benzoic acid is replaced with an equal amount of 4-(piperazine-1-yl)benzoic acid.

[0062] Example 6

[0063] The difference between Example 6 and Example 4 is that the amount of 4-(4-methylpiperazine)benzoic acid added is 5 parts.

[0064] Comparative Example 1

[0065] A method for preparing a long-life, wear-resistant cable includes the following steps:

[0066] S1. Styrene-butadiene rubber is extruded onto the outside of a copper conductor to obtain a semi-finished product;

[0067] S2. Mix 100 parts styrene-butadiene rubber, 12 parts nitrile rubber, 35 parts carbon black N110, 4 parts aromatic oil, and 18 parts carbon black N330.

[0068] 3 parts dioctyl phthalate, 3 parts sulfur, 2.5 parts accelerator NS, and 2 parts antioxidant 4010NA are mixed and kneaded at 55 r / min for 12 min. The mixture is then extruded onto the outside of the semi-finished product to obtain a sheath layer. After vulcanization, a high-life, wear-resistant cable is obtained.

[0069] Comparative Example 2

[0070] A method for preparing a long-life, wear-resistant cable includes the following steps:

[0071] S1. Styrene-butadiene rubber is extruded onto the outside of a copper conductor to obtain a semi-finished product;

[0072] S2. Mix 100 parts of styrene-butadiene rubber and 12 parts of acrylonitrile rubber, then add 21 parts of carbon black N110 and 2 parts of aromatic oil. After mixing for 1 minute, add 14 parts of carbon black N110 and mix at 70 r / min for 6 minutes to obtain mixed rubber A.

[0073] S3. Mix mixed rubber A with 18 parts carbon black N330 and 2 parts aromatic oil, and then mix at 70 r / min for 4 min to obtain mixed rubber B.

[0074] S4. Mix the mixed adhesive B with 3 parts dioctyl phthalate, 3 parts sulfur, 2.5 parts accelerator NS and 2 parts antioxidant 4010NA. After mixing at 70 r / min for 2 min, extrude the mixture onto the outside of the semi-finished product to obtain the sheath layer. After vulcanization, a high-life wear-resistant cable is obtained.

[0075] Experimental Example 1

[0076] The abrasion resistance of the sheath layers of the high-life abrasion-resistant cables prepared in Examples 1-3 and Comparative Examples 1-2 was tested according to the test methods specified in GB / T 9867-2008 "Determination of abrasion resistance of vulcanized rubber or thermoplastic rubber (rotary roller abrasion tester method)".

[0077] The test results are shown in Table 1:

[0078] Table 1 Performance test results of the high-life abrasion-resistant cables prepared in Examples 1-3 and Comparative Examples 1-2

[0079]

[0080] As shown in Table 1, when carbon black is added in stages and the mixing is carried out in three stages, with the first mixing speed being 42~48 r / min and the time being 5~6 min, the second mixing speed being 60~70 r / min and the time being 3.5~4 min, and the third mixing speed being 50~55 r / min and the time being 2~3 min, the wear resistance of the cable can be improved.

[0081] Experiment Example 2

[0082] The sheath layer of the high-life wear-resistant cables prepared in Examples 2 and 4-6 was tested according to the test methods specified in GB / T 2951.11-2008 "General Test Methods for Insulation and Sheath Materials of Cables and Optical Fibers - Part 11: General Test Methods - Measurement of Thickness and Dimensions - Mechanical Properties Test". The tensile strength of the specimen was tested. The specimen was prepared by cutting the sheath along the cable axis and cutting a narrow strip to make a small dumbbell specimen with a thickness of 2.0 mm, which is the test specimen.

[0083] The test results are shown in Table 2:

[0084] Table 2 Performance test results of the high-life abrasion-resistant cables prepared in Examples 2 and 4-6

[0085]

[0086] As shown in Table 2, the mechanical properties of the cable can be improved by pretreating carbon black N110 with piperazine benzoic acid compound.

[0087] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-life, wear-resistant cable, characterized in that, The material comprises, from the inside out, a conductor, an insulating layer, and a sheath layer. The sheath layer comprises the following raw materials in parts by weight: 100 parts styrene-butadiene rubber, 10-15 parts nitrile rubber, 30-40 parts carbon black N110, 15-20 parts carbon black N330, 2-4 parts plasticizer, 2-4 parts vulcanizing agent, 2-3 parts accelerator, 3-5 parts aromatic oil, and 1-3 parts antioxidant. The preparation method of the sheath layer includes the following steps: S1. Mix styrene-butadiene rubber and nitrile rubber, add 60wt% carbon black N110 and 50wt% aromatic oil, mix and then add 40wt% carbon black N110. After one internal mixing, obtain mixed rubber A. S2. Mix the mixed rubber A with carbon black N330 and 50wt% aromatic oil, and then perform a second internal mixing to obtain mixed rubber B. S3. Mix the mixed adhesive B with the remaining sheath layer raw materials, and after three intensive mixing processes, extrude it onto the outside of the insulation layer to obtain the sheath layer; The first internal mixing is performed at a speed of 42-48 r / min for 5-6 min, the second internal mixing is performed at a speed of 60-70 r / min for 3.5-4 min, and the third internal mixing is performed at a speed of 50-55 r / min for 2-3 min.

2. The high-life, wear-resistant cable according to claim 1, characterized in that, The conductor is made of copper.

3. The high-life, wear-resistant cable according to claim 1, characterized in that, The insulating layer is made of styrene-butadiene rubber.

4. The high-life, wear-resistant cable according to claim 1, characterized in that, The plasticizer includes one or more of dioctyl phthalate, dibutyl phthalate, and diisodecyl phthalate.

5. The high-life, wear-resistant cable according to claim 1, characterized in that, The vulcanizing agent includes one or more of sulfur, benzoyl peroxide, and dicumyl peroxide.

6. The high-life, wear-resistant cable according to claim 1, characterized in that, The accelerator includes one or more of accelerator DM, accelerator TMTD, and accelerator NS.

7. A high-life, wear-resistant cable according to claim 1, characterized in that, The antioxidant includes one or more of antioxidant 2246, antioxidant 4010NA, and antioxidant MB.

8. A high-life, wear-resistant cable according to claim 1, characterized in that, The carbon black N110 is pretreated carbon black N110. The preparation method of the pretreated carbon black N110 includes the following steps: dispersing piperazine benzoic acid compound in a solvent, adding carbon black N110, mixing and drying to obtain pretreated carbon black N110.

9. A high-life, wear-resistant cable according to claim 8, characterized in that, The piperazine benzoic acid compound includes one or both of 4-(4-methylpiperazine)benzoic acid and 4-(piperazine-1-yl)benzoic acid.

10. A method for preparing a high-life, wear-resistant cable, used to prepare the high-life, wear-resistant cable according to any one of claims 1 to 9, characterized in that, The process includes the following steps: after sequentially setting an insulation layer and a sheath layer on the outside of the conductor, vulcanization is performed to obtain a high-life, wear-resistant cable.

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