Composite cable and production process thereof

Abstract

The invention discloses a composite cable and a production process thereof, the composite cable comprises a wire core, a filling layer, an outer shielding layer, an outer insulating layer and a protective layer which are sequentially arranged from inside to outside, the wire core comprises a metal inner core, an inner insulating layer, an inner shielding layer and a wrapping layer which are sequentially arranged from inside to outside, the raw materials of the inner insulating layer comprise the following components: polyvinyl chloride, polytetrafluoroethylene, a plasticizer, an auxiliary agent, a flame retardant and an anti-aging agent; according to the composite cable and the production process thereof, the insulation effect of the cable can be effectively improved by adopting dual protection of the inner insulation layer and the outer insulation layer, and meanwhile, the shielding performance of the cable can be effectively improved by adopting dual protection of the inner shielding layer and the outer shielding layer, so that the overall performance of the composite cable can be improved; therefore, convenience is brought to the use of the composite cable.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing technology, specifically to a composite cable and its manufacturing process. Background Technology

[0002] A cable is an electrical energy or signal transmission device, typically composed of several or groups of conductors, and has the characteristics of internal current transmission and external insulation. Cables can be used to transmit electrical (magnetic) energy and information, realizing electromagnetic energy conversion. There are many types of cables, including composite cables, power cables, control cables, compensating cables, shielded cables, and high-temperature cables. Among them, composite cables are a type of special cable that integrates multiple functional units (such as power transmission, signal communication, and control circuits) into the same cable body through structural innovation. They can simultaneously meet the needs of power supply and information transmission and are widely used in energy, communication, and transportation fields. According to the patent application CN119786142A, a composite fire-resistant and flame-retardant cable and its manufacturing process are known prior art. Although the composite cable produced by this patent has advantages such as good flame retardancy, the technical solution of this patent still has the following defects in actual use: since the insulation layer only uses a single cross-linked ethylene propylene diene monomer (EPDM) rubber material, the overall insulation performance of the cable is poor. At the same time, the inner shielding layer uses a single material copper wire braided layer, which makes the overall shielding effect of the cable poor. Therefore, we propose a composite cable and its manufacturing process. Summary of the Invention

[0003] The purpose of this invention is to provide a composite cable and its manufacturing process to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a composite cable, comprising, from the inside out, a conductor, a filling layer, an outer shielding layer, an outer insulation layer, and a protective layer; The wire core includes a metal inner core, an inner insulation layer, an inner shielding layer, and a wrapping layer arranged sequentially from the inside out. The raw materials of the inner insulation layer include the following components: polyvinyl chloride, polytetrafluoroethylene, plasticizer, auxiliary agent, flame retardant and anti-aging agent, wherein the mass fraction of each component is polyvinyl chloride (30%-50%), polytetrafluoroethylene (20%-30%), plasticizer (10%-20%), auxiliary agent (5%-15%), flame retardant (1%-10%) and anti-aging agent (1%-10%), and the total proportion of each component is 100%. The inner shielding layer is woven from copper wires and aluminum wires in a way that interweaves warp and weft threads to form an inner shielding structure, and the wrapping layer is made of glass fiber material. The outer shielding layer is prepared by mixing copper foil, resin material and graphene; The raw materials of the outer insulation layer include the following components: silicone rubber, chlorosulfonated polyethylene rubber, compatibilizer, reinforcing agent and aluminum hydroxide, wherein the mass fraction of each component is silicone rubber (50%-70%), chlorosulfonated polyethylene rubber (10%-30%), compatibilizer (5%-15%), reinforcing agent (1%-10%) and aluminum hydroxide (1%-10%), and the total proportion of each component is 100%.

[0005] Preferably, the proportions of each component of the inner insulation layer by mass fraction percentage are as follows: 40% polyvinyl chloride, 25% polytetrafluoroethylene, 15% plasticizer, 10% auxiliary agent, 5% flame retardant and 5% anti-aging agent, and the total proportion of each component is 100%.

[0006] Preferably, the plasticizer is dioctyl sebacate and nano-alumina, and the mass fraction ratio of dioctyl sebacate to nano-alumina is 2:1.

[0007] Preferably, the auxiliary agent is methanol and carbon fiber, the mass fraction ratio of methanol and carbon fiber is 1:1.5, the flame retardant is a halogen-free flame retardant, and the anti-aging agent is a thioester.

[0008] Preferably, the method for preparing the inner insulating layer includes the following steps: Step 1: Weigh an appropriate amount of polyvinyl chloride and add it to mixer No. 1. Then add a portion of the weighed plasticizer to mixer No. 1 to premix the polyvinyl chloride and some of the plasticizer. Step 2: Weigh out an appropriate amount of polytetrafluoroethylene and add it to mixer No. 2. Then add the remaining plasticizer from step 1 to mixer No. 2 to premix the polytetrafluoroethylene and the remaining plasticizer. Step 3: After the materials in Mixer 1 and Mixer 2 have been mixed, first transfer the mixture from Mixer 1 to Mixer 2, and then add the auxiliary agent into Mixer 2 in two batches until the mixture from Step 1 and Step 2 can be fully blended. Step 4: Add the weighed flame retardant and anti-aging agent to the No. 2 mixer in Step 3 in sequence until the flame retardant and anti-aging agent are fully dispersed in the mixture to obtain the required inner insulation layer material.

[0009] Preferably, the proportions of each component of the outer insulation layer by mass fraction percentage are as follows: 60% silicone rubber, 20% chlorosulfonated polyethylene rubber, 10% compatibilizer, 5% reinforcing agent and 5% aluminum hydroxide, and the total proportion of each component is 100%.

[0010] Preferably, the compatibilizer is an ethylene-vinyl acetate-maleic anhydride copolymer, and the reinforcing agent is dioctyl terephthalate and chlorinated liquid nitrile rubber, wherein the mass fraction ratio of dioctyl terephthalate and chlorinated liquid nitrile rubber is 1:1.

[0011] Preferably, the method for preparing the outer insulating layer includes the following steps: Step 1: Weigh an appropriate amount of silicone rubber and add it to a mixing tank. Then, slowly add the compatibilizer in three portions, with each portion having a compatibilizer ratio of 3:2:1. Simultaneously, stir and mix the silicone rubber and compatibilizer at a temperature of approximately 120℃-180℃ for 5-8 minutes. Step 2: Add the pre-weighed chlorosulfonated polyethylene rubber granules to the mixing tank from Step 1, and control the mixing temperature at around 100℃-110℃. Observe the fusion state of the chlorosulfonated polyethylene rubber until there are no particulate substances in the slurry. Step 3: Divide the pre-weighed reinforcing agent into two portions and add them sequentially to the mixing tank from Step 1. Then, continue adding the weighed aluminum hydroxide until the slurry is fully mixed, thereby obtaining the required outer insulation layer material.

[0012] Preferably, the filling layer is a composite fiber material; the protective layer is a wear-resistant and flame-retardant coating.

[0013] A manufacturing process for a composite cable includes the following steps: S1. Using a wire drawing machine, the metal material is stretched into multiple strands of metal wire of the corresponding diameter, and the multiple strands of metal wire are twisted together so that the cross-section of the multiple strands of metal wire is circular, thereby forming the required metal core. Then, using an extruder, the prepared inner insulation layer material is uniformly coated on the outside of the metal core, thereby forming an inner insulation layer of uniform thickness on the outside of the metal core. S2. Using a braiding machine, copper and aluminum wires are braided by interlacing warp and weft threads to form an inner shielding mesh structure. The inner shielding mesh structure is then wrapped around the outer side of the inner insulation layer in step S1 to form an inner shielding layer. A glass fiber material wrapping layer is then evenly wrapped around the outer side of the formed inner shielding layer to prepare the required wire core. S3. After the wire core is prepared, multiple sets of wire cores are integrated together, and composite fiber material is added between the multiple sets of wire cores to form a filling layer. Then, an outer shielding layer made of copper foil, resin material and graphene is wrapped around the outside of the wire core and the filling layer. S4. Then, using an extruder, the prepared outer insulation material is evenly coated onto the outside of the outer shielding layer to form an outer insulation layer of uniform thickness. Next, using a spraying device, wear-resistant and flame-retardant coating is sprayed onto the outside of the outer insulation layer to form a protective layer. Finally, using a drying device, the protective layer is cured to produce the required composite cable.

[0014] Compared with the prior art, the beneficial effects of the present invention are: This composite cable and its manufacturing process, through the use of double protection of inner and outer insulation layers, can effectively improve the insulation effect of the cable itself. At the same time, the use of double protection of inner and outer shielding layers can also effectively improve the shielding performance of the cable itself. This can improve the overall performance of the composite cable, thus bringing convenience to its use. This composite cable and its manufacturing process utilize dioctyl sebacate and nano-alumina to plasticize polyvinyl chloride (PVC) and polytetrafluoroethylene (PTFE), respectively, thereby significantly improving the toughness, electrical insulation, and weather resistance of both PVC and PTFE. Simultaneously, methanol and carbon fiber enable better dispersion and fusion of PVC and PTFE during mixing, effectively combining their individual properties and thus significantly enhancing the flexibility, high-temperature resistance, and electrical insulation performance of the inner insulation layer material. This composite cable and its manufacturing process utilize ethylene-vinyl acetate-maleic anhydride copolymer to fully fuse silicone rubber and chlorosulfonated polyethylene rubber together, allowing the properties of silicone rubber and chlorosulfonated polyethylene rubber to be combined and exerted. At the same time, the addition of dioctyl phthalate and chlorinated liquid nitrile rubber can enhance the elasticity of silicone rubber and chlorosulfonated polyethylene rubber, thereby giving the prepared outer insulation layer material good high or low temperature resistance (i.e., weather resistance), oil resistance, acid and alkali resistance, high resilience and electrical insulation properties. This composite cable and its manufacturing process utilize the bonding properties of resin materials in the outer shielding layer to combine copper foil and graphene together, and leverage the properties of copper foil and graphene for double protection, thereby improving the cable's shielding performance. The inner shielding layer is woven from two different metal materials, and also utilizes the properties of copper wire and aluminum wire for double protection, further enhancing the cable's shielding performance. Attached Figure Description

[0015] Figure 1 This is a cross-sectional view of the composite cable structure of the present invention.

[0016] In the diagram: 1. Wire core; 11. Metal inner core; 12. Inner insulation layer; 13. Inner shielding layer; 14. Wrapping layer; 2. Filling layer; 3. Outer shielding layer; 4. Outer insulation layer; 5. Protective layer. Detailed Implementation

[0017] The present invention will be further described below with reference to embodiments.

[0018] The following embodiments are used to illustrate the present invention, but should not be used to limit the scope of protection of the present invention. The conditions in the embodiments can be further adjusted according to specific conditions, and simple improvements to the method of the present invention under the premise of the concept of the present invention are all within the scope of protection claimed by the present invention.

[0019] A composite cable includes, from the inside out, a conductor 1, a filling layer 2 (made of composite fiber material), an outer shielding layer 3, an outer insulation layer 4, and a protective layer 5 (made of wear-resistant and flame-retardant coating). The conductor 1 includes, from the inside out, a metal inner core 11, an inner insulation layer 12, an inner shielding layer 13, and a wrapping layer 14 (made of glass fiber material). Example 1:

[0020] The raw materials of the inner insulation layer 12 include the following components: polyvinyl chloride, polytetrafluoroethylene, plasticizer, auxiliary agent, flame retardant (halogen-free flame retardant) and anti-aging agent (thioester). The proportions of each component of the inner insulation layer 12 by mass fraction percentage are as follows: polyvinyl chloride 40%, polytetrafluoroethylene 25%, plasticizer 15%, auxiliary agent 10%, halogen-free flame retardant 5%, and thioester 5%, with the total proportion of each component being 100%. Among them, the plasticizer is dioctyl sebacate and nano alumina, and the mass fraction ratio of dioctyl sebacate and nano alumina is 2:1. The auxiliary agent is methanol and carbon fiber, and the mass fraction ratio of methanol and carbon fiber is 1:1.5. The method for preparing the inner insulating layer 12 includes the following steps: Step 1: Weigh an appropriate amount of polyvinyl chloride and add it to mixer No. 1. Then add a portion of the weighed plasticizer (dioctyl sebacate) to mixer No. 1 to premix the polyvinyl chloride and dioctyl sebacate. Step 2: Weigh out an appropriate amount of polytetrafluoroethylene and add it to mixer No. 2. Then add the remaining plasticizer (nano alumina) from step 1 to mixer No. 2 to premix the polytetrafluoroethylene and nano alumina. Step 3: After the materials in Mixer 1 and Mixer 2 are mixed, first transfer the mixture from Mixer 1 to Mixer 2, and then add the auxiliary agent (a mixture of methanol and carbon fiber) into Mixer 2 in two batches until the mixtures from Step 1 and Step 2 are fully blended. Step 4: Add the weighed halogen-free flame retardant and thioesters to the No. 2 mixer in Step 3 in sequence until the halogen-free flame retardant and thioesters are fully dispersed in the mixture to obtain the required inner insulation layer material.

[0021] Example 2:

[0022] The difference between this embodiment and Embodiment 1 is that the proportions of each component of the inner insulation layer 12 are as follows: 40% polyvinyl chloride, 25% polytetrafluoroethylene, 10% plasticizer, 15% auxiliary agent, 5% halogen-free flame retardant and 5% thioester, and the total proportion of each component is 100%. Example 3:

[0023] The difference between this embodiment and Embodiment 1 is that the proportions of each component of the inner insulation layer 12 are as follows: 40% polyvinyl chloride, 25% polytetrafluoroethylene, 20% plasticizer, 5% auxiliary agent, 5% halogen-free flame retardant and 5% thioester, and the total proportion of each component is 100%. By using the raw material ratios of the inner insulation layer 12 in Examples 1, 2, and 3 above to prepare the inner insulation layer material, and by conducting relevant performance tests on the prepared inner insulation layer material, it can be seen that: Polyvinyl chloride (PVC) is a common insulating material in cable production due to its excellent electrical insulation, chemical resistance, and mechanical strength, low cost, and easy processing. Polytetrafluoroethylene (PTFE), on the other hand, has stable chemical properties and extremely high temperature resistance, and is often used in special environments (such as chemical and high-temperature environments). PTFE also has good flexibility and elasticity, which can enhance the flexibility, elasticity, and high-temperature resistance of cables during the preparation of cable insulation materials. For plasticizers (dioctyl sebacate and nano-alumina), plasticizers are used to enhance the toughness of the material itself. The mixture of polyvinyl chloride (PVC) and dioctyl sebacate can improve the flexibility, cold resistance and weather resistance of PVC. At the same time, dioctyl sebacate has high plasticizing efficiency for PVC, low volatility, and good heat resistance, cold resistance and electrical insulation. The mixture of polytetrafluoroethylene (PTFE) and nano-alumina can enhance the toughness of PTFE itself. For the additives (methanol and carbon fiber), during the mixing of polyvinyl chloride and polytetrafluoroethylene, methanol can further improve the dispersion effect between the two, while carbon fiber can improve the compatibility and mechanical properties of the polyvinyl chloride and polytetrafluoroethylene mixture, and can respectively improve the heat resistance of polyvinyl chloride and the wear resistance of polytetrafluoroethylene.

[0024] In the above scheme, for Example 1, since the plasticizer and auxiliary agent ratios are 15% and 10% respectively, the ratios are relatively moderate. This allows dioctyl sebacate and nano-alumina to plasticize polyvinyl chloride (PVC) and polytetrafluoroethylene (PTFE) respectively, resulting in a general improvement in the toughness, electrical insulation, and weather resistance of PVC and PTFE. Meanwhile, methanol and carbon fiber enable better dispersion and fusion of PVC and PTFE during mixing, thus better combining the individual properties of PVC and PTFE, thereby significantly improving the flexibility, high temperature resistance, and electrical insulation performance of the inner insulation layer material. In the above scheme, for Example 2, since the plasticizer and auxiliary agent ratios are 10% and 15% respectively, the plasticizer ratio is too low and the auxiliary agent ratio is too high. This makes it difficult for dioctyl sebacate and nano-alumina to effectively plasticize polyvinyl chloride and polytetrafluoroethylene, respectively. In other words, the performance improvement effect on the two materials is poor. At the same time, although methanol and carbon fiber can make polyvinyl chloride and polytetrafluoroethylene more compatible, the flexibility of the prepared inner insulation layer material will be poor. In the above scheme, specifically for Example 3, the plasticizer and auxiliary agent ratios are 20% and 5%, respectively. That is, the plasticizer ratio is relatively high and the auxiliary agent ratio is relatively low. Although dioctyl sebacate and nano-alumina can effectively plasticize polyvinyl chloride and polytetrafluoroethylene, respectively, and improve the toughness and electrical insulation of the materials, the low content of methanol and carbon fiber makes it difficult for polyvinyl chloride and polytetrafluoroethylene to fully fuse when they are mixed. In other words, it is difficult to fully combine and utilize the individual properties of polyvinyl chloride and polytetrafluoroethylene, resulting in poor high-temperature resistance of the prepared inner insulation layer material. In summary, a comparison of Examples 1, 2, and 3 shows that the inner insulation layer material prepared using the raw material ratio of the inner insulation layer 12 in Example 1 has the best flexibility, high temperature resistance, and electrical insulation properties.

[0025] Example 4:

[0026] The difference between this embodiment and Embodiment 1 is that the operation steps of the method for preparing the inner insulating layer 12 are as follows: Step 1: Weigh out appropriate amounts of polyvinyl chloride and polytetrafluoroethylene and add them to the mixer in sequence. Then, add the weighed auxiliary agent (a mixture of methanol and carbon fiber) into the mixer in two batches to allow the vinyl chloride and polytetrafluoroethylene to fuse together. Step 2: Weigh out an appropriate amount of plasticizer (dioctyl sebacate and nano alumina) and slowly add the plasticizer to the mixture in Step 1 to facilitate the plasticization of polyvinyl chloride and polytetrafluoroethylene by dioctyl sebacate and nano alumina, respectively. Step 3: Add the weighed halogen-free flame retardant and thioesters to the mixer in Step 2 in sequence until the halogen-free flame retardant and thioesters are fully dispersed in the mixture to obtain the required inner insulation layer material.

[0027] Example 5:

[0028] The difference between this embodiment and Embodiment 1 is that the operation steps of the method for preparing the inner insulating layer 12 are as follows: Step 1: Weigh out appropriate amounts of polyvinyl chloride and polytetrafluoroethylene, and add them sequentially to the mixer. Weigh out an appropriate amount of plasticizer (dioctyl sebacate and nano alumina) and slowly add the plasticizer to the mixture to facilitate the plasticization of polyvinyl chloride and polytetrafluoroethylene by dioctyl sebacate and nano alumina, respectively. Step 2: Weigh out an appropriate amount of auxiliary agent (a mixture of methanol and carbon fiber) and add it to the mixture in Step 1 in two batches. This will promote better integration between the mixtures. Step 3: Add the weighed halogen-free flame retardant and thioesters to the mixer in Step 2 in sequence until the halogen-free flame retardant and thioesters are fully dispersed in the mixture to obtain the required inner insulation layer material.

[0029] The inner insulation layer material prepared by the production steps of the inner insulation layer 12 in Examples 1, 4, and 5 described above, and the relevant performance tests of the inner insulation layer material, show that: In the above scheme, for Example 1, since polyvinyl chloride and dioctyl sebacate, polytetrafluoroethylene and nano-alumina are mixed separately in advance, polyvinyl chloride and polytetrafluoroethylene can be plasticized separately in advance. This facilitates the enhancement of the toughness and electrical insulation of polyvinyl chloride and polytetrafluoroethylene in advance. Then, the plasticized polyvinyl chloride and polytetrafluoroethylene are mixed and an auxiliary agent (a mixture of methanol and carbon fiber) is added. This makes the plasticized and performance-enhanced polyvinyl chloride and polytetrafluoroethylene more compatible, and facilitates the combination of the original properties of polyvinyl chloride and polytetrafluoroethylene and the properties after plasticization, thereby significantly improving the flexibility, high temperature resistance and electrical insulation performance of the inner insulation layer material. In the above scheme, for Example 4, polyvinyl chloride and polytetrafluoroethylene are first fused together by adding an auxiliary agent (a mixture of methanol and carbon fiber), and then a plasticizer (dioctyl sebacate and nano-alumina) is added to the fused mixture to plasticize it. However, due to the poor fusion effect between nano-alumina and polyvinyl chloride, and the poor fusion effect between dioctyl sebacate and polytetrafluoroethylene, it is difficult to fully exert the plasticizing effect of dioctyl sebacate and nano-alumina, which will result in poor flexibility and electrical insulation performance of the final inner insulation layer material. In the above scheme, for Example 5, when polyvinyl chloride, polytetrafluoroethylene and plasticizers (dioctyl sebacate and nano-alumina) are mixed first, the fusion effect between nano-alumina and polyvinyl chloride is poor, and the fusion effect between dioctyl sebacate and polytetrafluoroethylene is also poor. This will first result in poor plasticizing effect of polyvinyl chloride and polytetrafluoroethylene themselves. At the same time, the fusion is then carried out using an auxiliary agent (a mixture of methanol and carbon fiber), which will further worsen the compatibility between polyvinyl chloride and polytetrafluoroethylene. As a result, the flexibility, high temperature resistance and electrical insulation performance of the final inner insulation layer material are all poor. In summary, a comparison of Examples 1, 4, and 5 shows that the inner insulation layer material prepared using the inner insulation layer 12 production step of Example 1 has the best flexibility, high temperature resistance, and electrical insulation properties.

[0030] Example 6:

[0031] The raw materials of the outer insulation layer 4 include the following components: silicone rubber, chlorosulfonated polyethylene rubber, compatibilizer (ethylene-vinyl acetate-maleic anhydride copolymer), reinforcing agent and aluminum hydroxide. The proportions of each component of the outer insulation layer 4 by mass fraction percentage are as follows: silicone rubber 60%, chlorosulfonated polyethylene rubber 20%, ethylene-vinyl acetate-maleic anhydride copolymer 10%, reinforcing agent 5% and aluminum hydroxide 5%, and the total proportion of each component is 100%. Among them, the reinforcing agent is dioctyl terephthalate and chlorinated liquid nitrile rubber, and the mass fraction ratio of dioctyl terephthalate and chlorinated liquid nitrile rubber is 1:1. The method for preparing the outer insulating layer 4 includes the following steps: Step 1: Weigh an appropriate amount of silicone rubber and add it to a mixing tank. Then, slowly add the ethylene-vinyl acetate-maleic anhydride copolymer in three portions, with each addition of the ethylene-vinyl acetate-maleic anhydride copolymer in a ratio of 3:2:1. At the same time, stir and mix the silicone rubber and the ethylene-vinyl acetate-maleic anhydride copolymer at a temperature of about 120℃-180℃ for 5-8 minutes. Step 2: Add the pre-weighed chlorosulfonated polyethylene rubber granules to the mixing tank from Step 1, and control the mixing temperature at around 100℃-110℃. Observe the fusion state of the chlorosulfonated polyethylene rubber until there are no particulate substances in the slurry. Step 3: Divide the pre-weighed reinforcing agent (dioctyl terephthalate and chlorinated liquid nitrile rubber) into two portions and add them sequentially to the mixing tank in Step 1. Then add the weighed aluminum hydroxide until the slurry is fully mixed to obtain the required outer insulation layer material.

[0032] Example 7:

[0033] The difference between this embodiment and Embodiment Six is ​​that the proportions of each component in the outer insulation layer 4 are as follows: 60% silicone rubber, 20% chlorosulfonated polyethylene rubber, 5% ethylene-vinyl acetate-maleic anhydride copolymer, 10% reinforcing agent, and 5% aluminum hydroxide, with the total proportion of each component being 100%. Example 8:

[0034] The difference between this embodiment and Embodiment Six is ​​that the proportions of each component in the outer insulation layer 4 are as follows: 60% silicone rubber, 20% chlorosulfonated polyethylene rubber, 14% ethylene-vinyl acetate-maleic anhydride copolymer, 1% reinforcing agent, and 5% aluminum hydroxide, with the total proportion of each component being 100%. The outer insulation layer material was prepared using the raw material ratios and method steps described in Examples 6, 7, and 8 above. Relevant performance tests were performed on the prepared outer insulation layer material, and the results showed that: Due to the excellent heat resistance and UV resistance of silicone rubber, when silicone rubber is used in the outer insulation layer of cables, the cables can be used in high-temperature and outdoor environments. At the same time, chlorosulfonated polyethylene rubber has outstanding oil resistance, chemical resistance and weather resistance. When chlorosulfonated polyethylene rubber is used in the outer insulation layer of cables, the cables can be used in outdoor or chemically exposed environments. For the compatibilizer (ethylene-vinyl acetate-maleic anhydride copolymer), its non-polar segment (ethylene) has good compatibility with silicone rubber, and its polar group (maleic anhydride) can react with the sulfinyl chloride group of chlorosulfonated polyethylene rubber to form a "bridge" effect, which enables better compatibility between silicone rubber and chlorosulfonated polyethylene rubber. For reinforcing agents (dioctyl terephthalate and chlorinated liquid nitrile rubber), dioctyl terephthalate is an environmentally friendly plasticizer with good compatibility. It can be used as a softener in rubber products, especially in cable materials where it has a good plasticizing effect and low volatility. It is suitable for cable materials that require heat resistance and high insulation. Chlorinated liquid nitrile rubber has good interfacial compatibility and significantly improves the adhesion and affinity of materials. At the same time, it also has good physical properties, high strength, acid and alkali resistance, low temperature resistance and high resilience, and also has a certain plasticizing effect when used.

[0035] In the above scheme, specifically for Example 6, since the proportions of compatibilizer and reinforcing agent are 10% and 5% respectively, the ethylene-vinyl acetate-maleic anhydride copolymer can fully fuse silicone rubber and chlorosulfonated polyethylene rubber together, allowing the properties of silicone rubber and chlorosulfonated polyethylene rubber to be combined and exerted. At the same time, the addition of dioctyl phthalate and chlorinated liquid nitrile rubber can enhance the elasticity of silicone rubber and chlorosulfonated polyethylene rubber, thereby giving the prepared outer insulation layer material good high or low temperature resistance (i.e., weather resistance), oil resistance, acid and alkali resistance, and high resilience.

[0036] In the above scheme, specifically for Example 7, the proportions of compatibilizer and reinforcing agent are 5% and 10%, respectively. Due to the low content of compatibilizer, it is difficult for silicone rubber and chlorosulfonated polyethylene rubber to be well compatible. This will cause interference between silicone rubber and chlorosulfonated polyethylene rubber, resulting in the inability to fully utilize the various properties of silicone rubber and chlorosulfonated polyethylene rubber.

[0037] In the above scheme, for Example 8, since the proportions of compatibilizer and reinforcing agent are 14% and 1% respectively, the proportion of reinforcing agent is relatively low. This makes it difficult to effectively improve the properties of the compatible silicone rubber and chlorosulfonated polyethylene rubber, resulting in a weakening of the physical properties, high strength, acid and alkali resistance, low temperature resistance and high resilience of the rubber material.

[0038] In summary, based on the comparison of Examples 6, 7, and 8, it can be seen that the outer insulation layer material prepared using the raw material ratio and method steps of Example 6 has the best high or low temperature resistance (i.e., weather resistance), oil resistance, acid and alkali resistance, and high resilience.

[0039] Example 9:

[0040] This embodiment improves the outer shielding layer 3 and inner shielding layer 13 of the composite cable. The outer shielding layer 3 is prepared by mixing copper foil, resin material and graphene. The preparation steps of the outer shielding layer 3 are as follows: First, the resin material is melted in a heating container and graphene powder is slowly added and mixed. Then, after the graphene powder and resin material are fully fused, the mixture is cooled. Stirring cannot be stopped. Finally, after the mixture has cooled down, the mixture is coated onto the copper foil using a coating device, thereby forming the required copper foil outer shielding structure. The inner shielding layer 13 is woven from copper wires and aluminum wires using a method of interlacing warp and weft threads to form an inner shielding structure; The advantages of this embodiment are as follows: the outer shielding layer 3 utilizes the bonding properties of resin materials to combine copper foil and graphene together, and utilizes the properties of copper foil and graphene for double protection, thereby improving the shielding performance of the cable. The inner shielding layer 13 is woven from two different metal materials, and can also utilize the properties of copper wire and aluminum wire for double protection, thereby further improving the shielding performance of the cable.

[0041] Example 10:

[0042] This embodiment, combining Embodiments 1, 6, and 9, proposes a manufacturing process for composite cables, including the following steps: S1. Using a wire drawing machine, the metal material is stretched into multiple strands of metal wire of corresponding diameter, and the multiple strands of metal wire are twisted together so that the cross-section of the multiple strands of metal wire is circular, thereby forming the required metal core 11. Then, using an extruder, the inner insulation layer material prepared in Example 1 is uniformly coated on the outside of the metal core 11, thereby forming an inner insulation layer 12 of uniform thickness on the outside of the metal core 11. S2. Using a braiding machine, copper wire and aluminum wire are braided in a way that the warp and weft threads are interlaced to form an inner shielding mesh structure. The inner shielding mesh structure is then wrapped around the outer side of the inner insulation layer 12 in step S1 to form an inner shielding layer 13. Then, a glass fiber material wrapping layer 14 is evenly wrapped around the outer side of the formed inner shielding layer 13 to prepare the required wire core 1. S3. After the core 1 is prepared, multiple sets of core 1 are integrated together, and composite fiber material is added in the gaps between the multiple sets of core 1 to form a filling layer 2. Then, an outer shielding layer 3, which is made of copper foil, resin material and graphene, is wrapped around the outside of the core 1 and the filling layer 2. S4. Then, using an extruder, the outer insulation layer material prepared in Example 6 is uniformly coated on the outside of the outer shielding layer 3 to form an outer insulation layer 4 with uniform thickness. Next, using a spraying equipment, wear-resistant and flame-retardant coating is sprayed on the outside of the outer insulation layer 4 to form a protective layer 5. Finally, the protective layer 5 is cured using a drying equipment to prepare the required composite cable.

[0043] In the above scheme, it should be noted that the composite cable prepared in this embodiment adopts double protection of inner insulation layer 12 and outer insulation layer 4, which can effectively improve the insulation effect of the cable itself. At the same time, the double protection of inner shielding layer 13 and outer shielding layer 3 also effectively improves the shielding performance of the cable itself.

[0044] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A composite cable, characterized in that, It includes, from the inside out, a wire core (1), a filling layer (2), an outer shielding layer (3), an outer insulation layer (4), and a protective layer (5); The wire core (1) includes a metal inner core (11), an inner insulation layer (12), an inner shielding layer (13), and a wrapping layer (14) arranged sequentially from the inside to the outside. The raw materials of the inner insulation layer (12) include the following components: polyvinyl chloride, polytetrafluoroethylene, plasticizer, auxiliary agent, flame retardant and anti-aging agent, wherein the mass fraction of each component is polyvinyl chloride (30%-50%), polytetrafluoroethylene (20%-30%), plasticizer (10%-20%), auxiliary agent (5%-15%), flame retardant (1%-10%) and anti-aging agent (1%-10%), and the total proportion of each component is 100%. The inner shielding layer (13) is woven from copper wire and aluminum wire in a way that the warp and weft are interlaced to form an inner shielding structure, and the wrapping layer (14) is made of glass fiber material; The outer shielding layer (3) is prepared by mixing copper foil, resin material and graphene; The raw materials of the outer insulation layer (4) include the following components: silicone rubber, chlorosulfonated polyethylene rubber, compatibilizer, reinforcing agent and aluminum hydroxide, wherein the mass fraction of each component is silicone rubber (50%-70%), chlorosulfonated polyethylene rubber (10%-30%), compatibilizer (5%-15%), reinforcing agent (1%-10%) and aluminum hydroxide (1%-10%), and the total proportion of each component is 100%.

2. The composite cable according to claim 1, characterized in that, The proportions of each component of the inner insulation layer (12) by mass fraction percentage are as follows: 40% polyvinyl chloride, 25% polytetrafluoroethylene, 15% plasticizer, 10% auxiliary agent, 5% flame retardant and 5% anti-aging agent, and the total proportion of each component is 100%.

3. A composite cable according to claim 2, characterized in that, The plasticizer is dioctyl sebacate and nano-alumina, and the mass fraction ratio of dioctyl sebacate to nano-alumina is 2:

1.

4. A composite cable according to claim 2, characterized in that, The auxiliary agent is methanol and carbon fiber, and the mass fraction ratio of methanol to carbon fiber is 1:1.

5. The flame retardant is a halogen-free flame retardant, and the anti-aging agent is a thioester.

5. A composite cable according to claim 2, characterized in that, The method for preparing the inner insulating layer (12) includes the following steps: Step 1: Weigh an appropriate amount of polyvinyl chloride and add it to mixer No.

1. Then add a portion of the weighed plasticizer to mixer No. 1 to premix the polyvinyl chloride and some of the plasticizer. Step 2: Weigh out an appropriate amount of polytetrafluoroethylene and add it to mixer No.

2. Then add the remaining plasticizer from step 1 to mixer No. 2 to premix the polytetrafluoroethylene and the remaining plasticizer. Step 3: After the materials in Mixer 1 and Mixer 2 have been mixed, first transfer the mixture from Mixer 1 to Mixer 2, and then add the auxiliary agent into Mixer 2 in two batches until the mixture from Step 1 and Step 2 can be fully blended. Step 4: Add the weighed flame retardant and anti-aging agent to the No. 2 mixer in Step 3 in sequence until the flame retardant and anti-aging agent are fully dispersed in the mixture to obtain the required inner insulation layer material.

6. A composite cable according to claim 1, characterized in that, The proportions of each component of the outer insulation layer (4) by mass fraction percentage are as follows: 60% silicone rubber, 20% chlorosulfonated polyethylene rubber, 10% compatibilizer, 5% reinforcing agent and 5% aluminum hydroxide, and the total proportion of each component is 100%.

7. A composite cable according to claim 6, characterized in that, The compatibilizer is an ethylene-vinyl acetate-maleic anhydride copolymer, and the reinforcing agent is dioctyl terephthalate and chlorinated liquid nitrile rubber, wherein the mass fraction ratio of dioctyl terephthalate and chlorinated liquid nitrile rubber is 1:

1.

8. A composite cable according to claim 6, characterized in that, The method for preparing the outer insulating layer (4) includes the following steps: Step 1: Weigh an appropriate amount of silicone rubber and add it to a mixing tank. Then, slowly add the compatibilizer in three portions, with each portion having a compatibilizer ratio of 3:2:

1. Simultaneously, stir and mix the silicone rubber and compatibilizer at a temperature of approximately 120℃-180℃ for 5-8 minutes. Step 2: Add the pre-weighed chlorosulfonated polyethylene rubber granules to the mixing tank from Step 1, and control the mixing temperature at around 100℃-110℃. Observe the fusion state of the chlorosulfonated polyethylene rubber until there are no particulate substances in the slurry. Step 3: Divide the pre-weighed reinforcing agent into two portions and add them sequentially to the mixing tank from Step 1. Then, continue adding the weighed aluminum hydroxide until the slurry is fully mixed, thereby obtaining the required outer insulation layer material.

9. A composite cable according to claim 1, characterized in that, The filling layer (2) is a composite fiber material; the protective layer (5) is a wear-resistant and flame-retardant coating.

10. The manufacturing process of a composite cable according to claims 1-9, characterized in that, Includes the following steps: S1. Using a wire drawing machine, the metal material is stretched into multiple strands of metal wire of the corresponding diameter, and the multiple strands of metal wire are twisted together so that the cross-section of the multiple strands of metal wire is circular, thereby forming the required metal core (11). Then, the prepared inner insulation layer material is uniformly coated on the outside of the metal core (11) using an extruder, thereby forming a uniformly thick inner insulation layer (12) on the outside of the metal core (11). S2. Using a braiding machine, the copper wire and aluminum wire are braided by interlacing the warp and weft to form an inner shielding mesh structure. The inner shielding mesh structure is then wrapped around the outer side of the inner insulation layer (12) in step S1 to form an inner shielding layer (13). The glass fiber material wrapping layer (14) is then evenly wrapped around the outer side of the formed inner shielding layer (13) to prepare the required wire core (1). S3. After the core (1) is prepared, multiple cores (1) are integrated together, and composite fiber material is added in the gap between the multiple cores (1) to form a filling layer (2). Then, an outer shielding layer (3) made of copper foil, resin material and graphene is wrapped around the core (1) and the filling layer (2). S4. Then, using an extruder, the prepared outer insulation layer material is uniformly coated on the outside of the outer shielding layer (3) to form an outer insulation layer (4) with uniform thickness. Next, using a spraying equipment, wear-resistant and flame-retardant coating is sprayed on the outside of the outer insulation layer (4) to form a protective layer (5). Finally, using a drying equipment, the protective layer (5) is cured to prepare the required composite cable.

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