High-strength heat-resistant lightweight green aluminum alloy cable

Abstract

The application belongs to the technical field of aluminum alloy cables, and discloses a high-strength heat-resistant lightweight green aluminum alloy cable, which comprises, from inside to outside, a silver-aluminum alloy conductive core, a conductor shielding layer, an insulation layer, an insulation shielding layer, a PP filling rope, a non-woven fabric tape, a steel tape and a heat-resistant flame-retardant waterproof outer sheath layer; the silver-aluminum alloy conductive core comprises, by weight percentage, Cu 0.01-0.3%, Fe 0.3-0.8%, Si 0.03-0.1%, Zn 0.01-0.05%, Mg 0.02-0.05%, B 0.001-0.04%, Ag 0.01-0.08%, and the balance of Al; the conductor strength and the conductive performance are improved through the silver-copper micro-alloying effect synergistic wire drawing film process; the outer sheath layer uses polydimethylmethylhydrogen siloxane grafted waterproof agent and 4-vinyl aniline polymer as a functional modifier, and is compounded with PVC to endow the cable with excellent heat resistance, flame retardance and waterproof properties.

Description

Technical Field

[0001] This invention relates to the field of aluminum alloy cable technology, specifically to a high-strength, heat-resistant, lightweight, and green aluminum alloy cable. Background Technology

[0002] Compared to copper core cables, aluminum alloy cables are lower in cost and consume fewer resources. Their key performance indicators, such as conductivity, mechanical properties, and corrosion resistance, have reached or are close to those of copper cables. However, some problems remain. Aluminum alloy cables have relatively poor conductor strength. Under sustained external forces such as bending and stretching, they can break and cause breakdowns, leading to fires and severely impacting circuit operation. Furthermore, the conductivity of aluminum alloy cables is still lower than that of copper cables. In addition, the traditional round conductor compression technique is often used during conductor compaction, resulting in a lower conductor fill factor, poorer single-wire contact tightness, and higher contact resistance, leading to greater energy loss and contradicting the concept of energy conservation and emission reduction. Moreover, the insulation and sheathing layers covering the aluminum alloy conductors are mostly made of moisture-resistant polymers such as polyvinyl chloride or cross-linked polyethylene. However, these polymers have high dielectric loss during use, are prone to aging and cracking, and allow moisture penetration, leading to decreased insulation performance and causing leakage or breakdown. Summary of the Invention

[0003] To overcome the shortcomings of the existing technology, the present invention provides a high-strength, heat-resistant, lightweight, and green aluminum alloy cable. The high-strength, heat-resistant, lightweight, and green aluminum alloy cable comprises, from the inside out, a silver-aluminum alloy conductive core, a conductor shielding layer, an insulation layer, an insulation shielding layer, PP filler rope, non-woven fabric wrapping tape, steel tape, and a heat-resistant, flame-retardant, and waterproof outer sheath layer. The conductor shielding layer includes an inner shielding material and an outer shielding material, and is produced using a double-layer co-extrusion process. The conductor shielding layer, insulation layer, insulation shielding layer, and outer sheath layer are extruded onto the surface using an extruder. The heat-resistant, flame-retardant, and waterproof outer sheath layer is obtained by extruding a heat-resistant, flame-retardant, and waterproof outer sheath layer composite material. The addition of highly conductive silver atoms replaces the aluminum lattice, increasing the concentration of free electrons, reducing resistivity, and thus improving conductivity. Simultaneously, silver can synergistically form a composite reinforcing phase with copper, hindering dislocation movement. Furthermore, the solid solution aging heat treatment process optimizes the internal grain structure of the aluminum alloy, enhances the connection strength between grain boundaries, and improves mechanical strength, ensuring that the stranded silver-aluminum alloy wires do not break under significant tensile force. The cable conductor also employs a profiled compaction structure technology, ensuring tight bonding between conductors, increasing the filler density and contact area, effectively reducing resistance, and imparting longitudinal water-blocking properties to prevent water tree formation. In the heat-resistant, flame-retardant, and waterproof outer sheath, a heat-resistant, flame-retardant, and waterproof agent is introduced. This agent contains hydrophobic F atoms and a non-polar polysiloxane structure, which can reduce water absorption and inhibit the material from absorbing water, thus preventing a decline in cable insulation performance and extending service life. The decomposition or activation of the siloxane structure can catalyze cross-linking between copolymer molecular chains, promoting combustion into char rather than generating volatile combustibles, and synergistically achieving flame retardancy with the halogens in the sheath-level soft polyvinyl chloride. In addition, the polysiloxane has high bond energies of -Si-O-Si and -Si-C bonds, exhibiting thermal stability, which can effectively improve the heat resistance of the cable.

[0004] The purpose of this invention is to provide a high-strength, heat-resistant, lightweight, and green aluminum alloy cable.

[0005] This invention is achieved through the following technical solution:

[0006] A high-strength, heat-resistant, lightweight, and green aluminum alloy cable, comprising, from the inside out, a silver-aluminum alloy conductive core, a conductor shielding layer, an insulation layer, an insulation shielding layer, PP filler rope, non-woven fabric wrapping tape, steel tape, and a heat-resistant, flame-retardant, and waterproof outer sheath. The silver-aluminum alloy conductive core, by weight percentage, comprises: Cu 0.01-0.3%, Fe 0.3-0.8%, Si 0.03-0.1%, Zn 0.01-0.05%, Mg 0.02-0.05%, B 0.001-0.04%, Ag 0.01-0.08%, with the balance being Al. The heat-resistant, flame-retardant, and waterproof outer sheath, by weight, comprises 100 parts polyvinyl chloride, 2-8 parts heat-resistant, flame-retardant, and waterproofing agent, and 5-15 parts compatibilizer. The heat-resistant, flame-retardant, and waterproofing agent is a polydimethylsiloxane grafted waterproofing agent and 4-vinylaniline.

[0007] The conductor shielding layer comprises an inner shielding material and an outer shielding material, and is produced using a double-layer co-extrusion process. The conductor shielding layer, the insulation layer, the insulation shielding layer, and the heat-resistant, flame-retardant, and waterproof outer sheath layer are obtained by extruding and coating the surface using an extruder.

[0008] In one specific embodiment, the structural formula of the waterproofing agent is shown in Formula 1: Formula 1.

[0009] In one specific embodiment, the structural formula of the polydimethylmethylhydrosiloxane is shown in Formula 2: Equation 2.

[0010] In one specific embodiment, the inner shielding material of the conductor shielding layer is PYJD-10 kV, and the outer shielding material is PYJBJ-10 kV; the insulation layer is a cross-linked insulation material; the insulating shielding layer is a semi-conductive nylon tape; the PP filler rope has a fineness of 12kD and a twisted diameter of 1.5 mm; the non-woven fabric wrapping tape is a 0.2±0.03 mm thick plain weave non-woven fabric; and the steel strip is a 0.2 mm galvanized steel strip with armor.

[0011] In one specific embodiment, the preparation of the silver-aluminum alloy conductive core includes the following steps:

[0012] S1. Pretreatment: Remove the oxide layer and impurities from the surface of the aluminum strip and copper rod with sandpaper and cut them into small pieces of 10*10 mm; vacuum dry AlSi master alloy, AlZn master alloy, AlFe master alloy, AlMg master alloy and AlB master alloy at 80-100 ℃; soak the silver wire in dilute hydrochloric acid for 5-10 minutes to remove the surface oxide film, rinse with distilled water and air dry;

[0013] S2. Under argon conditions, aluminum strip is added to a melting furnace and melted at 730-750 ℃; copper rod and pre-molten AlFe master alloy are added and stirred for 5-10 minutes; AlSi master alloy and AlZn master alloy are added and stirred for 5-10 minutes; then AlMg master alloy, AlB master alloy and silver wire are added and stirred for 10-20 minutes to obtain silver-aluminum alloy melt.

[0014] S3. Argon gas is introduced, and a low-sodium refining agent is added to refine the silver-aluminum alloy molten liquid. The liquid is then filtered, cooled to 710-730℃, and cast and cooled to obtain a silver-aluminum alloy ingot. The ingot is then subjected to solution treatment and aging treatment, followed by softening and pressing treatment to produce a silver-aluminum alloy rod.

[0015] S4. The silver-aluminum alloy rod is drawn into wire by a wire drawing process to prepare silver-aluminum alloy wire of the required diameter; then the silver-aluminum alloy wire is stranded and annealed to obtain a silver-aluminum alloy conductive core.

[0016] In one specific embodiment, the refining agent in step S3 is a low-sodium refining agent, the dosage of which is 0.05-0.1% of the mass of the silver-aluminum alloy molten liquid, the refining time is 6-12 minutes, and the mixture is allowed to stand for 25-60 minutes after refining; the solution temperature is 520-540 ℃, and the time is 2-4 hours; the aging treatment temperature is 160-180 ℃, and the time is 4-8 hours; the softening temperature is 300-350 ℃, and the time is 1-2 hours.

[0017] In one specific embodiment, the annealing temperature in step S4 is 320-350 ℃, and the time is 2-3 hours; the diameter of the silver-aluminum alloy wire is 6-20 mm, and the fill factor of the silver-aluminum alloy wire is 0.96.

[0018] In one specific embodiment, the preparation of the heat-resistant, flame-retardant, and waterproof outer sheath composite material includes the following steps:

[0019] S1. Waterproofing agent preparation

[0020] S1-1. Under nitrogen atmosphere, dry tetrafluorohydroquinone and dichlorodimethyl-3,3,3-fluoropropylsilane were dissolved in anhydrous toluene; an amine catalyst was added, and the mixture was stirred at 60-80 °C for 10-16 hours; the mixture was cooled, filtered, and the filtrate was concentrated to obtain product A;

[0021] S1-2. Under a nitrogen atmosphere, dry product A, alkali and polymerization inhibitor are dissolved in anhydrous DMF and activated at 45-55 °C for 20-40 minutes; p-bromostyrene is added dropwise and reacted at 80-100 °C for 12-24 hours; after cooling, saturated brine is used for salting out, and the product is purified by column chromatography to obtain the waterproofing agent.

[0022] S2. Preparation of heat-resistant, flame-retardant, and waterproof agent

[0023] Under a nitrogen atmosphere, dry polydimethylmethylhydrosiloxane and a polymerization inhibitor are dissolved in anhydrous toluene and heated to 60-85 °C; a waterproofing agent solution and a 4-vinylaniline solution dissolved in a small amount of anhydrous toluene are added dropwise; a platinum catalyst solution dissolved in a small amount of anhydrous toluene is added, and the reaction is carried out for 4-10 hours; the mixture is cooled, concentrated, and purified by column chromatography to obtain a heat-resistant, flame-retardant, and waterproofing agent.

[0024] S3. Preparation of heat-resistant, flame-retardant, and waterproof outer sheath composite material

[0025] Under vacuum conditions, heat-resistant, flame-retardant, and waterproof agent, polyvinyl chloride, and compatibilizer are added to the mixing tank of an extruder and melt-mixed at a temperature of 160-200 ℃ and 300-400 rpm; extruded melt-blended; and then pelletized by a water-cooled stripping and pelletizing machine to obtain a heat-resistant, flame-retardant, and waterproof outer sheath composite material with a particle size of 2-3 mm.

[0026] In one specific embodiment, the amount of dichlorodimethyl-3,3,3-fluoropropylsilane used in step S1-1 is 0.95-1 times the molar amount of tetrafluorohydroquinone; the amine catalyst is N,N-diisopropylethylamine, and the amount used is 1.01-1.1 times the molar amount of tetrafluorohydroquinone.

[0027] In one specific embodiment, the alkali in steps S1-2 is cesium carbonate, and the amount used is 2-4 times the molar amount of product A; the polymerization inhibitor is hydroquinone, and the amount used is 0.1-0.5% of the mass of p-bromostyrene; the amount of p-bromostyrene used is 1.05-1.5 times the molar amount of product A.

[0028] In one specific embodiment, the polymerization inhibitor in step S2 is 2,6-di-tert-butyl-p-cresol, and the amount used is 0.1-0.5% of the total mass of the waterproofing agent and 4-vinylaniline; the amount of the waterproofing agent is 2.34-2.92 times the molar amount of silane in polydimethylmethylhydrosiloxane; the amount of 4-vinylaniline is 0.59-1.17 times the molar amount of silane in polydimethylmethylhydrosiloxane; and the platinum catalyst is a Karstedt catalyst, and the amount used is 0.01-0.05% of the total mass of polydimethylmethylhydrosiloxane, the waterproofing agent, and 4-vinylaniline.

[0029] In one specific embodiment, the compatibilizer in step S3 is polypropylene grafted with maleic anhydride, and the polyvinyl chloride is a protective layer-grade soft polyvinyl chloride.

[0030] Beneficial effects

[0031] This invention provides a high-strength, heat-resistant, lightweight, and green aluminum alloy cable. The high-strength, heat-resistant, lightweight, and green aluminum alloy cable comprises, from the inside out, a silver-aluminum alloy conductive core, a conductor shielding layer, an insulation layer, an insulation shielding layer, PP filler rope, non-woven fabric wrapping tape, steel tape, and a heat-resistant, flame-retardant, and waterproof outer sheath layer. The conductor shielding layer includes an inner shielding material and an outer shielding material, and is produced using a double-layer co-extrusion process. The conductor shielding layer, insulation layer, insulation shielding layer, and outer sheath layer are extruded onto the surface using an extruder. The heat-resistant, flame-retardant, and waterproof outer sheath layer is obtained by extruding a heat-resistant, flame-retardant, and waterproof outer sheath layer composite material. The addition of highly conductive silver atoms, which replace aluminum lattice, increases the concentration of free electrons, reduces resistivity, and imparts high conductivity to the cable. Simultaneously, silver can synergistically form a composite reinforcing phase with copper, hindering dislocation movement. Furthermore, the solid solution aging heat treatment process optimizes the internal grain structure of the aluminum alloy, enhances the connection strength between grain boundaries, and improves the mechanical strength of the conductor, ensuring that the stranded silver-aluminum alloy wires do not break under significant tensile force. The cable conductor also employs a profiled compaction structure technology, ensuring tight bonding between conductors, increasing the filler density and contact area, further reducing resistance, and imparting longitudinal water-blocking properties to prevent water treeing. In the heat-resistant, flame-retardant, and waterproof outer sheath, a heat-resistant, flame-retardant, and waterproof agent is introduced. This agent contains hydrophobic F atoms and a non-polar polysiloxane structure, which can reduce water absorption and inhibit the material from absorbing water, thus preventing a decline in cable insulation performance and extending service life. The decomposition or activation of the siloxane structure can catalyze cross-linking between copolymer molecular chains, promoting combustion into char rather than generating volatile combustibles, and synergistically achieving flame retardancy with the halogens in the sheath-level soft polyvinyl chloride. In addition, the polysiloxane has high bond energies of -Si-O-Si and -Si-C bonds, exhibiting thermal stability and effectively improving the cable's heat resistance. Attached Figure Description

[0032] Figure 1 The synthesis route of the waterproofing agent;

[0033] Figure 2 The hydrogen nuclear magnetic resonance spectrum of the waterproofing agent;

[0034] Figure 3 Infrared spectra of polydimethylmethylhydrosiloxane and heat-resistant, flame-retardant, and waterproofing agent. Detailed Implementation

[0035] 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.

[0036] Unless otherwise specified, the experimental methods used in the embodiments are conventional methods, and the materials and reagents used are commercially available unless otherwise specified.

[0037] The raw materials used in the examples and comparative examples are described below:

[0038] Polydimethylmethylhydrosiloxane: viscosity 55-65 mm² / s (25 °C), hydrogen content 1.15-1.25%;

[0039] Outer sheath: Sheath-grade soft polyvinyl chloride, grade H-70, purchased from Guangdong Boyou Polymer Materials Co., Ltd.;

[0040] Compatibilizer: Polypropylene grafted with maleic anhydride, product number P478291, Mn3900, grafting rate 8-10 wt%, purchased from Shanghai Aladdin Biochemical Technology Co., Ltd.

[0041] Aluminum strip: Grade 2.0*316C, purchased from Foshan Baizheng Trade Co., Ltd.;

[0042] Copper rod: 8.0 mm, purchased from Qingyuan Xinghai Copper Industry Co., Ltd.;

[0043] AlSi master alloy: grade AlSi20, containing 20% ​​Si, purchased from Sitong New Materials R&D Center;

[0044] AlZn master alloy: grade AlZn10, containing 10% Zn, purchased from Sitong New Materials R&D Center;

[0045] AlFe master alloy: grade AlFe20, containing 20%Fe, purchased from Sitong New Materials R&D Center;

[0046] AlMg master alloy: grade AlMg20, containing 20% ​​Mg, purchased from Sitong New Materials R&D Center;

[0047] AlB master alloy: grade AlB3, containing 3% B, purchased from Sitong New Materials R&D Center;

[0048] Silver wire: 99.99% high-purity silver wire, purchased from Kairui New Materials (Beijing) Technology Co., Ltd.;

[0049] Refining agent: Low sodium refining agent, STJ-A3, powder, purchased from Sitong New Materials R&D Center;

[0050] Conductor shielding layer: Inner shielding material, PYJD-10 kV, purchased from Jiangyin Haijiang Polymer Materials Co., Ltd.;

[0051] Conductor shielding layer: outer shielding material, PYJBJ-10 kV, purchased from Jiangyin Haijiang Polymer Materials Co., Ltd.;

[0052] Insulation layer: Cross-linked insulation material, 10 kV, purchased from Guangzhou Panyu Guangyao Xinghan Plastics Co., Ltd.;

[0053] Insulating shielding layer: semi-conductive nylon tape, 0.12*40 mm, purchased from Shenyang Dongshuo Electric Materials Co., Ltd.;

[0054] PP filled rope: fineness 12kD, specific gravity 1.33 g / m, twisted diameter 1.5 mm, purchased from Jiangxi Longtai New Material Co., Ltd.

[0055] Non-woven fabric strap: Plain weave non-woven fabric, 0.2±0.03 mm thick, 16*8 cm in size, purchased from Suzhou Taiyuan New Electronics Co., Ltd.

[0056] Steel strip: 0.2 mm galvanized steel strip, armored, 30 mm wide, purchased from Ningjin County Haoxin New Material Technology Co., Ltd.;

[0057] Waterproofing agent: Homemade, preparation method as follows:

[0058] S1. Under nitrogen atmosphere, dry tetrafluorohydroquinone (1 molar equivalent) was dissolved in anhydrous toluene and stirred until dissolved; dry dichloromethyl-3,3,3-fluoropropylsilane (0.95-1 molar equivalent) was added; N,N-diisopropylethylamine (1.01-1.1 molar equivalent) was slowly added dropwise, and the mixture was heated to 60-80 °C and stirred for 10-16 hours until the reaction was complete; the mixture was cooled, filtered, and the filtrate was concentrated to obtain product A, with a yield of 88%.

[0059] S2. Under a nitrogen atmosphere, dry product A (1 molar equivalent), cesium carbonate (2-4 molar equivalents), and polymerization inhibitor hydroquinone (0.1-0.5 wt% of p-bromostyrene) are dissolved in anhydrous DMF and activated by stirring at 45-55 °C for 20-40 minutes. P-bromostyrene (1.05-1.5 molar equivalents) is slowly added dropwise, and the reaction is carried out at 80-100 °C for 12-24 hours until the reaction is complete. After cooling, the product is precipitated with saturated brine, filtered, and purified by column chromatography to obtain the waterproofing agent with a yield of 93%.

[0060] Heat-resistant, flame-retardant, and waterproofing agent: homemade, preparation method as follows:

[0061] Under a nitrogen atmosphere, dry polydimethylmethylhydrosiloxane (1 molar equivalent) and polymerization inhibitor 2,6-di-tert-butyl-p-cresol (0.1-0.5 wt% of the total mass of the waterproofing agent and 4-vinylaniline) are dissolved in anhydrous toluene and bubbled for 20-30 minutes; the mixture is heated to 60-85 °C, and a solution of waterproofing agent (2.34-2.92 molar equivalents) and 4-vinylaniline (0.59-1.17 molar equivalents) dissolved in a small amount of anhydrous toluene is slowly added dropwise; a solution of Karstedt catalyst (0.01-0.05 wt%) dissolved in a small amount of anhydrous toluene is added, and the reaction is carried out for 4-10 hours; the mixture is cooled, concentrated, and purified by column chromatography to obtain a heat-resistant, flame-retardant, and waterproofing agent.

[0062] Heat-resistant flame retardant: self-made. The preparation method is different from that of heat-resistant flame retardant waterproofing agent in that the waterproofing agent is replaced with 4-vinylaniline.

[0063] Heat-resistant, flame-retardant, and waterproof outer sheath composite material 1: Self-made, preparation method as follows:

[0064] Under vacuum conditions, 2 parts of heat-resistant, flame-retardant, and waterproof agent, 100 parts of protective layer-grade soft polyvinyl chloride, and 10 parts of compatibilizer polypropylene grafted maleic anhydride were added to the mixing tank of an extruder and melt-mixed at a temperature of 160-200 ℃ and 300-400 rpm; extruded and melt-blended; and then pelletized by a water-cooled stripping and pelletizing machine to obtain heat-resistant, flame-retardant, and waterproof outer sheath composite material 1 with a particle size of 2-3 mm.

[0065] Heat-resistant, flame-retardant, and waterproof outer sheath composite material 2: self-made. The difference between the preparation method and the heat-resistant, flame-retardant, and waterproof outer sheath composite material is that the amount of heat-resistant, flame-retardant, and waterproof agent used is 8 parts.

[0066] Heat-resistant and flame-retardant outer sheath composite material: self-made. The difference between the preparation method and the heat-resistant, flame-retardant and waterproof outer sheath composite material is that the heat-resistant, flame-retardant and waterproof agent is replaced with a heat-resistant flame retardant agent.

[0067] Silver-aluminum alloy conductive core 1: Self-made, preparation method is as follows:

[0068] S1. Pretreatment: Remove the oxide layer and impurities from the surface of the aluminum strip and copper rod with sandpaper and cut them into small pieces of 10*10 mm; vacuum dry AlSi master alloy, AlZn master alloy, AlFe master alloy, AlMg master alloy and AlB master alloy at 95 ℃; soak the silver wire in dilute hydrochloric acid for 7 minutes to remove the surface oxide film, rinse with distilled water and air dry.

[0069] S2. Under argon atmosphere, aluminum strip is added to a melting furnace and melted at 750 °C; copper rod and pre-molten AlFe master alloy are added and stirred for 8 minutes; AlSi master alloy and AlZn master alloy are added and stirred for 10 minutes; then AlMg master alloy, AlB master alloy and silver wire are added and stirred for 20 minutes to obtain silver-aluminum alloy melt; by weight percentage, it includes Cu (0.2%), Fe (0.5%), Si (0.08%), Zn (0.03%), Mg (0.05%), B (0.04%), Ag (0.05%), with the balance being Al;

[0070] S3. Argon gas is introduced, and a low-sodium refining agent (0.08% of the mass of the silver-aluminum alloy melt) is added to refine the silver-aluminum alloy melt for 10 minutes. The melt is then allowed to stand for 50 minutes, filtered, and cooled to 710-730 ℃ before casting and cooling to obtain a silver-aluminum alloy ingot. The ingot is then heated to 530 ℃ for solution treatment for 3.5 hours, cooled to 170 ℃ for aging treatment for 6 hours, softened at 330 ℃ for 1.5 hours, and then pressed to form a silver-aluminum alloy rod.

[0071] S4. Silver-aluminum alloy rods are drawn into wires by a wire drawing process to prepare silver-aluminum alloy wires with a diameter of 8 mm; then the silver-aluminum alloy wires are stranded and annealed at 340 ℃ for 2.5 hours to obtain silver-aluminum alloy conductive core 1.

[0072] Silver-aluminum alloy conductive core 2: Self-made. The preparation method is the same as that of the silver-aluminum alloy conductive core, except that the amount of silver wire used is 0.01wt%.

[0073] Silver-aluminum alloy conductive core 3: Self-made. The preparation method is the same as that of the silver-aluminum alloy conductive core, except that the amount of silver wire used is 0.08wt%.

[0074] Aluminum alloy conductive core: self-made. The difference between the preparation method and that of silver aluminum alloy conductive core is that no silver wire is added.

[0075] Unless otherwise specified, all components and raw materials used in the embodiments and comparative examples of this invention are commercially available, and the same type of components and raw materials are used in each parallel experiment.

[0076] Examples and Comparative Examples

[0077] A high-strength, heat-resistant, lightweight, and green aluminum alloy cable is comprising, from the inside out, a silver-aluminum alloy conductive core, a conductor shielding layer, an insulation layer, an insulation shielding layer, a PP filler rope, a non-woven fabric wrapping tape, a steel tape, and a heat-resistant, flame-retardant, and waterproof outer sheath layer. The conductor shielding layer includes an inner shielding material and an outer shielding material, which are produced using a double-layer co-extrusion process. The conductor shielding layer, insulation layer, insulation shielding layer, and heat-resistant, flame-retardant, and waterproof outer sheath layer composite material are extruded and coated onto the surface using an extruder. The heat-resistant, flame-retardant, and waterproof outer sheath layers 1 and 2 are respectively extruded from the heat-resistant, flame-retardant, and waterproof outer sheath layer composite material 1 and 2.

[0078] Example 1: The high-strength, heat-resistant, lightweight, green aluminum alloy cable consists of, from the inside out, a silver-aluminum alloy conductive core 1, a conductor shielding layer, an insulation layer, an insulation shielding layer, a PP filler rope, a non-woven fabric wrapping tape, a steel tape, and a heat-resistant, flame-retardant, and waterproof outer sheath layer 1.

[0079] Example 2: The high-strength, heat-resistant, lightweight, green aluminum alloy cable consists of, from the inside out, a silver-aluminum alloy conductive core 2, a conductor shielding layer, an insulation layer, an insulation shielding layer, a PP filler rope, a non-woven fabric wrapping tape, a steel tape, and a heat-resistant, flame-retardant, and waterproof outer sheath layer 1.

[0080] Example 3: The high-strength, heat-resistant, lightweight, green aluminum alloy cable consists of, from the inside out, a silver-aluminum alloy conductive core 3, a conductor shielding layer, an insulation layer, an insulation shielding layer, a PP filler rope, a non-woven fabric wrapping tape, a steel tape, and a heat-resistant, flame-retardant, and waterproof outer sheath layer 1.

[0081] Example 4: The high-strength, heat-resistant, lightweight, green aluminum alloy cable consists of, from the inside out, a silver-aluminum alloy conductive core 1, a conductor shielding layer, an insulation layer, an insulation shielding layer, a PP filler rope, a non-woven fabric wrapping tape, a steel tape, and a heat-resistant, flame-retardant, and waterproof outer sheath layer 2.

[0082] Comparative Example 1: The high-strength, heat-resistant, lightweight, and green aluminum alloy cable consists of, from the inside out, an aluminum alloy conductive core, a conductor shielding layer, an insulation layer, an insulation shielding layer, a PP filler rope, a non-woven fabric wrapping tape, a steel tape, and a heat-resistant, flame-retardant, and waterproof outer sheath layer 1.

[0083] Comparative Example 2: The high-strength, heat-resistant, lightweight, green aluminum alloy cable consists of, from the inside out, a silver-aluminum alloy conductive core 1, a conductor shielding layer, an insulation layer, an insulation shielding layer, a PP filler rope, a non-woven fabric wrapping tape, a steel tape, and a heat-resistant and flame-retardant outer sheath layer. The heat-resistant and flame-retardant outer sheath layer is obtained by extrusion of a heat-resistant and flame-retardant outer sheath layer composite material.

[0084] Comparative Example 3: The high-strength, heat-resistant, lightweight, green aluminum alloy cable consists of, from the inside out, a silver-aluminum alloy conductive core, a conductor shielding layer, an insulation layer, an insulation shielding layer, PP filler rope, non-woven fabric wrapping tape, steel tape, and a sheath layer made of soft polyvinyl chloride.

[0085] Test case

[0086] The high-strength, heat-resistant, lightweight, and green aluminum alloy cable prepared in the examples and comparative examples was subjected to the following performance tests, and the results are shown in the attached figures and Table 1, respectively.

[0087] 1. Proton NMR Spectroscopy: The synthesized waterproofing agent was dissolved in deuterated DMSO to prepare a 1.0 wt% solution. The NMR spectrum of the sample was measured using a proton NMR spectrometer at 400 MHz. The results are as follows: Figure 2 As shown in the figure, the integral score is consistent with the chemical environment and the sample, indicating that the target product was successfully synthesized.

[0088] 2. Infrared Spectroscopy: Polydimethylsiloxane and a heat-resistant, flame-retardant, and waterproofing agent were separately mixed with potassium bromide at a ratio of 1:50 to prepare tablets. An Avatar 380 spectrometer was used for this test. Before testing, a blank background was scanned, followed by the placement of the tablet sample for measurement. The scanning range was 500-4000 cm⁻¹. -1 The result is as follows Figure 3 As shown.

[0089] 3. Tensile strength and elongation at break: According to GB / T228.1-2010 "Metallic materials, tensile testing - Part 1: Test method at room temperature", a universal testing machine was used to test the tensile strength and tensile properties of a single strand of silver-aluminum alloy wire after stranding.

[0090] 4. Fatigue bending times: The number of times a single wire is repeatedly bent after being twisted together with silver-aluminum alloy wire.

[0091] 5. Conductivity: According to GB / T3048.2-2007 "Test Methods for Electrical Properties of Wires and Cables - Part 2: Test for Resistivity of Metallic Materials", the resistance of a single wire after stranding silver-aluminum alloy wire was measured using a QJ36S-2 DC low-resistance tester. The conductivity σ was then calculated using the following formula. Where σ is the conductivity (%IACS), ρ is the resistivity of standard soft copper at 20 °C, L is the length (m), and S is the cross-sectional area (mm²). 2 R represents the material resistance (Ω), and the ambient temperature for testing conductivity is 20 ℃.

[0092] 6. UL-94 Rating: Following the test method in GB / T 8332-2008 "Test Method for Burning Performance of Foamed Plastics - Horizontal Burning Method", a heat-resistant, flame-retardant, and waterproof outer sheath composite material is extruded to a size of 20*20*0.3 cm. A vertical pressure of 1.2 MPa is applied, followed by spray cooling and demolding to obtain sheets of the outer protective sheath and insulation layer. These sheets are then cut into 10 cm*1.3 cm*0.3 cm strips for testing. The UL-94 rating is determined based on the sample's burning behavior: V-0: Indicates the sample did not burn completely, and the molten droplets did not ignite the cotton; V-1: Indicates the sample did not burn completely, and the molten droplets did not ignite the cotton (the extinguishing time is longer than V-0); V-2: Indicates the sample did not burn completely, and the molten droplets ignited the cotton.

[0093] 7. Water resistance: Immerse the prepared cable in 60℃ water for 120 hours, withstand voltage at 2.5kV for 5 minutes, and observe whether breakdown occurs; bend the above cable 10 times, bend it 180 degrees, immerse it in 60℃ water for 120 hours, withstand voltage at 2.5kV for 5 minutes, and observe whether breakdown occurs.

[0094] 8. Heat resistance: After placing the manufactured cable in hot air at 125 ℃ for 168 hours, the decrease rate of the overall tensile strength of the cable is tested.

[0095] Table 1 Performance Test Results

[0096]

[0097] From the appendix Figure 3 As can be seen, in the spectrum of polydimethylmethylhydrosiloxane, the peak appears at 2965-2850 cm⁻¹. -1 The stretching vibrations attributed to CH2 peak at 2127 cm⁻¹. -1 The stretching vibrations, attributed to Si-H, peak at 1411 cm⁻¹. -1 1259 cm -1 This is the absorption signal of Si-CH3, with a peak at 790 cm⁻¹. -1 This is the absorption signal of Si(-CH3)2, with a peak at 10¹³ cm⁻¹. -1 The nearby area shows the absorption signal of Si-O-Si. In the spectrum of the heat-resistant, flame-retardant, and waterproof agent, the absorption signal is located at 3500-3300 cm⁻¹. -1 Stretching vibrations belonging to -NH- were observed at 1600-1430 cm⁻¹. -1 And stretching vibrations belonging to C=C on the benzene ring were observed, at 1250-1100 cm⁻¹. -1 Stretching vibrations belonging to the Ph-O-Ph group were observed at 830 cm⁻¹. -1The characteristic signal of para-benzene appeared at 1675 cm⁻¹, and the hydroxyl peak disappeared, also not appearing at 1675 cm⁻¹. -1 The observation of a peak belonging to alkenyl C=C indicates that Si-H reacts with the double bond, and the waterproofing agent and 4-vinylaniline were successfully grafted onto polydimethylmethylhydrosiloxane, thus successfully preparing a heat-resistant, flame-retardant, and waterproofing agent.

[0098] As can be seen from Table 1 of the examples and Comparative Example 1, the silver-aluminum alloy wires prepared by adding silver wire exhibit good mechanical properties after stranding. This is because silver can synergistically form a composite strengthening phase with copper, hindering dislocation movement, and, in conjunction with the solution aging heat treatment process, optimize the internal grain structure of the aluminum alloy, enhance the intergranular bonding strength, and improve mechanical strength, preventing the stranded silver-aluminum alloy wires from breaking under high tensile force. The decrease in tensile strength in Example 3 may be due to the increased silver content coarsening the grain boundaries to some extent, leading to stress concentration points. Example 2 has a lower silver content, resulting in fewer composite strengthening phases formed synergistically with copper, and less improvement in intergranular bonding strength; therefore, the stranded silver-aluminum alloy wires exhibit poorer tensile strength and fatigue resistance.

[0099] Silver is the metal with the best electrical conductivity. When silver atoms replace aluminum lattice, the concentration of free electrons increases and the resistivity decreases, thereby improving conductivity. Compared with Comparative Example 1, the conductivity of the embodiment increases to 60.22-61.84%, reducing power loss.

[0100] Furthermore, as shown in Examples 1 and 4 and Comparative Example 2, introducing a heat-resistant, flame-retardant, and waterproof agent into the outer sheath layer can effectively improve the waterproof performance of the cable. This agent contains hydrophobic F atoms and a non-polar polysiloxane structure, reducing water absorption and inhibiting the decrease in cable insulation performance caused by water absorption, thereby extending its service life. Meanwhile, as shown in Comparative Example 3, the polysiloxane has high bond energies for both the -Si-O-Si and -Si-C bonds, exhibiting thermal stability and effectively improving the cable's heat resistance, making it suitable for high-temperature operating environments.

[0101] The decomposition or activation of the siloxane structure contained in the heat-resistant, flame-retardant, and waterproof agent can catalyze cross-linking between copolymer molecular chains, promoting combustion into char rather than generating volatile combustibles. This, in conjunction with the halogens in the protective layer of soft polyvinyl chloride, achieves flame retardancy. Comparative Example 3, which does not contain the heat-resistant, flame-retardant, and waterproof agent, shows a relatively lower degree of weakening in its flame-retardant performance.

[0102] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A high-strength heat-resistant lightweight green aluminum alloy cable, characterized by, The high-strength heat-resistant lightweight green aluminum alloy cable comprises, from inside to outside, a silver-aluminum alloy conductive core, a conductor shielding layer, an insulation layer, an insulation shielding layer, a PP filling rope, a non-woven fabric tape, a steel tape and a heat-resistant flame-retardant waterproof outer sheath layer; the silver-aluminum alloy conductive core comprises, by weight percentage, Cu 0.01-0.3%, Fe 0.3-0.8%, Si 0.03-0.1%, Zn 0.01-0.05%, Mg 0.02-0.05%, B 0.001-0.04%, Ag 0.01-0.08%, and the balance of Al; The heat-resistant, flame-retardant and waterproof outer sheath layer comprises, by weight, 100 parts of polyvinyl chloride, 2-8 parts of heat-resistant, flame-retardant and waterproof agent, and 5-15 parts of compatibilizer, wherein the heat-resistant, flame-retardant and waterproof agent is obtained by grafting polydimethylmethylhydrogen siloxane with a waterproof agent and 4-vinyl aniline; and the waterproof agent has a structural formula as shown in Formula 1. Formula 1.

2. The high-strength heat-resistant lightweight green aluminum alloy cable according to claim 1, characterized by, The preparation of the silver-aluminum alloy conductive core comprises the following steps: S1. Pretreatment: remove the oxide layer and impurities on the surface of the aluminum strip and copper rod with sandpaper and cut into small pieces; vacuum dry AlSi intermediate alloy, AlZn intermediate alloy, AlFe intermediate alloy, AlMg intermediate alloy and AlB intermediate alloy at 80-100 ℃; immerse silver wire in dilute hydrochloric acid for 5-10 minutes to remove the surface oxide film, rinse with distilled water and air dry; S2. Under the condition of argon, add the aluminum strip to the smelting furnace and melt at 730-750 ℃; add the copper rod and pre-melted AlFe intermediate alloy and stir for 5-10 minutes; add AlSi intermediate alloy and AlZn intermediate alloy and stir for 5-10 minutes; then add AlMg intermediate alloy, AlB intermediate alloy and silver wire and stir for 10-20 minutes to obtain a silver-aluminum alloy molten liquid; S3. Pass in argon, add low-sodium refining agent to refine the silver-aluminum alloy molten liquid, filter, cool to 710-730 ℃ and then pour and cool to obtain a silver-aluminum alloy ingot; perform solid solution and aging treatment; then perform softening and pressing treatment to obtain a silver-aluminum alloy rod; S4. Draw the silver-aluminum alloy rod into a wire through a wire-drawing film process to obtain a silver-aluminum alloy wire with a desired diameter; then twist and anneal the silver-aluminum alloy wire to obtain a silver-aluminum alloy conductive core.

3. The high-strength heat-resistant lightweight green aluminum alloy cable according to claim 2, characterized by, The refining agent of step S3 is a low-sodium refining agent, and the amount used is 0.05-0.1% of the mass of the silver-aluminum alloy molten liquid, the refining time is 6-12 minutes, and the silver-aluminum alloy molten liquid is allowed to stand for 25-60 minutes after refining; the solid solution temperature is 520-540 ℃, and the time is 2-4 hours; the aging treatment temperature is 160-180 ℃, and the time is 4-8 hours; the softening temperature is 300-350 ℃, and the time is 1-2 hours; the annealing temperature of step S4 is 320-350 ℃, and the time is 2-3 hours; the diameter of the silver-aluminum alloy wire is 6-20 mm, and the filling factor of the silver-aluminum alloy wire is 0.

96.

4. The high-strength heat-resistant lightweight green aluminum alloy cable according to claim 1, characterized by, The preparation of the heat-resistant flame-retardant waterproof outer sheath layer composite material comprises the following steps: S1. Preparation of waterproof agent S1-1. Under the condition of nitrogen, dissolve dry tetrafluorohydroquinone and chlorodimethyl-3,3,3-fluoropropylsilane in anhydrous toluene; add an amine catalyst and stir at 60-80 ℃ for 10-16 hours; cool, filter and concentrate the filtrate to obtain product A; S1-2. Dry product A, base and polymerization inhibitor were dissolved in anhydrous DMF under nitrogen atmosphere, and activated at 45-55 ℃ for 20-40 min; p-bromostyrene was added dropwise, and reacted at 80-100 ℃ for 12-24 h; cooled, salted out with saturated brine, filtered, and purified by column chromatography to obtain the water repellent agent; S2. Preparation of heat-resistant flame-retardant water repellent agent Under nitrogen atmosphere, dry polydimethylmethylhydrogen siloxane and polymerization inhibitor were dissolved in anhydrous toluene, and heated to 60-85 ℃; a solution of water repellent agent and 4-vinylaniline dissolved in a small amount of anhydrous toluene was added dropwise; a solution of platinum catalyst dissolved in a small amount of anhydrous toluene was added, and reacted for 4-10 h; cooled, concentrated, and purified by column chromatography to obtain the heat-resistant flame-retardant water repellent agent; S3. Preparation of heat-resistant flame-retardant water repellent outer sheath layer composite material Under vacuum conditions, heat-resistant flame-retardant water repellent agent, polyvinyl chloride, and compatibilizer were added to the mixing barrel of the extruder, and melt-mixed at a temperature of 160-200 ℃ and a speed of 300-400 rpm; extruded into a melt blend; water-cooled to a draw bar, and cut into particles by a granulator to obtain a heat-resistant flame-retardant water repellent outer sheath layer composite material with a particle size of 2-3 mm.

5. The high strength heat resistant light weight green aluminum alloy cable as claimed in claim 4, wherein, The amount of chlorodimethyl-3,3,3-fluoropropylsilane in step S1-1 was 0.95-1 times the molar amount of tetrafluorohydroquinone; the amount of amine catalyst was 1.01-1.1 times the molar amount of tetrafluorohydroquinone; the amount of base in step S1-2 was 2-4 times the molar amount of product A; the amount of polymerization inhibitor was 0.1-0.5% of the mass of p-bromostyrene; and the amount of p-bromostyrene was 1.05-1.5 times the molar amount of product A.

6. The high strength heat resistant light weight green aluminum alloy cable as claimed in claim 4, wherein, The amount of polymerization inhibitor in step S2 was 0.1-0.5% of the mass of the water repellent agent and 4-vinylaniline; the amount of water repellent agent was 2.34-2.92 times the molar amount of silicon hydrogen in polydimethylmethylhydrogen siloxane; the amount of 4-vinylaniline was 0.59-1.17 times the molar amount of silicon hydrogen in polydimethylmethylhydrogen siloxane; the amount of platinum catalyst was 0.01-0.05% of the mass of polydimethylmethylhydrogen siloxane, water repellent agent, and 4-vinylaniline; and the compatibilizer in step S3 was polypropylene grafted maleic anhydride.

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