A method for preparing a corrosion-resistant composite cable conductor

Abstract

The application discloses a kind of preparation methods of corrosion-resistant composite cable conductor, it is related to alloy cable technical field, comprising: high-purity aluminum matrix and intermediate alloy containing conductivity promoting element are smelted, refined, cast, annealed, extruded and aged treatment after preparation aluminum alloy conductor mixture;Reinforcing fiber, polymer matrix, interface reinforcing agent and nano filler are mixed, and anti-creep reinforcing mixture is prepared;Aluminum alloy conductor mixture and anti-creep reinforcing mixture are prepared by co-extrusion process, and composite cable is obtained;Polymer matrix, interface reinforcing agent, functional filler and plasticizer are mixed, and corrosion-resistant protective layer is prepared on the outside of composite cable by surface activation and secondary extrusion process.The application is combined with the composite structure of anti-creep reinforcing layer and aluminum alloy conductor, which significantly improves the anti-creep ability of the cable;And corrosion-resistant protective layer is closely combined with composite cable, suitable for humid or salt spray environment.

Description

Technical Field

[0001] This invention relates to the field of alloy cable technology, and in particular to a method for preparing a corrosion-resistant composite cable conductor. Background Technology

[0002] With the rapid development of power transmission and communication technologies, the demand for cable conductors in power, communication, and transportation fields is increasing. Traditional copper conductors are widely used due to their high conductivity and good mechanical properties; however, copper is expensive and heavy, leading to high cable costs and installation difficulties. Aluminum alloy conductors, due to their light weight, low cost, and good conductivity, have become an ideal alternative to copper conductors. However, existing aluminum alloy conductors have the following problems:

[0003] Insufficient creep resistance: Aluminum alloys are prone to creep under long-term high temperature or mechanical load, which leads to cable deformation and stress relaxation, affecting service life and safety.

[0004] Poor corrosion resistance: In humid, salt spray or corrosive ion-containing environments, aluminum alloy conductors are prone to electrochemical corrosion, forming oxides or corrosion products on the surface, which reduces conductivity and mechanical strength. Summary of the Invention

[0005] To solve the above-mentioned technical problems, the present invention provides a method for preparing a corrosion-resistant composite cable conductor, the specific technical solution of which is as follows:

[0006] A method for preparing a corrosion-resistant composite cable conductor, wherein the corrosion-resistant composite cable conductor comprises, from the inside out, an aluminum alloy conductor, a creep-resistant reinforcing layer, and a corrosion-resistant protective layer, in weight percentages as follows:

[0007] The aluminum alloy conductor is composed of the following components: Si 0.4%~0.6%, Fe 0.1%~0.3%, Cu 0~0.05%, Mg 0.4%~0.6%, Zn 0.05%~0.1%, conductivity-enhancing elements 0.01%~0.08%, and the balance being Al, wherein the impurity element content in the aluminum alloy conductor does not exceed 0.03%;

[0008] The creep-resistant reinforcing layer is composed of the following components: 25%~40% reinforcing fibers, 58%~73% first polymer matrix, 0.5%~1.5% interface reinforcing agent, and 0.5%~2% nanofiller;

[0009] The corrosion-resistant protective layer is composed of the following components: 89%~95% second polymer matrix, 0.5%~1.0% interface reinforcing agent, 2%~5% functional filler, and 3%~6% plasticizer;

[0010] The preparation method includes the following steps:

[0011] a. An aluminum alloy conductor mixture is prepared by melting, refining, casting, annealing, extruding and aging a high-purity aluminum matrix and an intermediate alloy containing conductivity-enhancing elements;

[0012] b. Prepare a creep-resistant reinforced mixture by mixing reinforcing fibers, polymer matrix, interface reinforcing agent and nanofiller according to weight percentages;

[0013] c. The aluminum alloy conductor mixture and the creep-resistant reinforcement mixture are co-extruded to obtain a composite cable containing an aluminum alloy conductor and a creep-resistant reinforcement layer;

[0014] d. The polymer matrix, interface reinforcing agent, functional filler and plasticizer are formulated and mixed according to weight percentage, and a corrosion-resistant protective layer is prepared on the outside of the composite cable through surface activation and secondary extrusion process.

[0015] Preferably, the conductivity-enhancing elements include B, Zr, and rare earth elements, wherein the rare earth elements are selected from at least one of Ce, L, and Y; the intermediate alloy includes Al-B, Al-Zr, and rare earth element alloys, wherein the rare earth element alloys are selected from at least one of Al-Ce, Al-La, and Al-Y.

[0016] Preferably, the reinforcing fiber is selected from at least one of glass fiber, basalt fiber, and carbon fiber; the first polymer matrix is ​​selected from at least one of polyamide, polypropylene, and polyetheretherketone; the interface reinforcing agent is selected from at least one of silane coupling agent, titanate coupling agent, and maleic anhydride grafted polymer; and the nanofiller is selected from nano... ,nanometer ,nanometer At least one of the following: the second polymer matrix is ​​selected from at least one of polyvinyl chloride, polyethylene, and polyurethane; the functional filler is selected from nanomaterials. Nano ZnO, Nano At least one of the following: the plasticizer is selected from at least one of dioctyl phthalate, tributyl citrate, and epoxidized soybean oil.

[0017] Preferably, step a specifically includes the following sub-steps:

[0018] a1. Melt the high-purity aluminum matrix and the intermediate alloy containing conductivity-enhancing elements at 750~780℃ and hold for 20~40 minutes;

[0019] a2. Argon purging and The refining agent removes gases and inclusions; the purging time is 10-15 minutes.

[0020] a3. Continuous casting to form aluminum alloy bars with a diameter of 10~15 mm, with a cooling rate of 10~15℃ / s;

[0021] a4.510~530℃ for 5~7 hours, then rapidly water-cooled to room temperature;

[0022] a5.440~490℃ extrusion to form an aluminum alloy conductor mixture with a diameter of 3~5 mm;

[0023] Keep warm at 170~210℃ for 6~10 hours.

[0024] Preferably, step b specifically includes the following sub-steps:

[0025] b1. Mix the reinforcing fiber, the first polymer matrix, the interface reinforcing agent and the nanofiller according to the weight percentage, and granulate them using a twin-screw extruder;

[0026] b2. Dry the mixture after batching at 80~120℃ for 2~4 hours to obtain the creep-resistant reinforced mixture.

[0027] Preferably, step c specifically includes the following sub-steps:

[0028] c1. Micro-arc oxidation or chemical coupling treatment is applied to the surface of aluminum alloy conductor mixture to form an oxide film or coupling layer;

[0029] c2. A composite cable containing an aluminum alloy conductor and an anti-creep reinforcement layer is prepared by simultaneously extruding an aluminum alloy conductor mixture and an anti-creep reinforcement mixture using a multi-layer co-extruder at an extrusion temperature of 180~380℃.

[0030] c3. Cool to room temperature with water.

[0031] Preferably, step d specifically includes the following sub-steps:

[0032] d1. Mix the second polymer matrix, interface reinforcing agent, functional filler and plasticizer according to the weight percentage, and granulate using a single screw extruder;

[0033] d2. Perform plasma treatment or chemical coupling treatment on the surface of the creep-resistant reinforcement layer of the composite cable for 30-60 seconds;

[0034] d3. The mixture after batching is extruded onto the surface of the composite cable using a single screw extruder at an extrusion temperature of 160~210℃ to form a corrosion-resistant protective layer;

[0035] d4. Cool the air to room temperature.

[0036] Preferably, in step c1, the chemical coupling treatment specifically includes: immersing the aluminum alloy conductor mixture in a 1%~3% concentration silane coupling agent solution for 1~3 minutes, and drying it at 80~120℃ for 1~2 hours to form a silane coupling layer; in step d2, the chemical coupling treatment specifically includes: immersing the composite cable in a 1%~3% concentration titanate coupling agent solution for 30~60 seconds, and drying it at 80~120℃ for 1~2 hours to form a titanate coupling layer.

[0037] Preferably, the reinforcing fiber is obtained by modifying it through the following steps:

[0038] The reinforcing fibers are ultrasonically cleaned in ethanol or acetone solution for 10-20 minutes to remove surface impurities.

[0039] Under an inert gas atmosphere, the cleaned reinforcing fibers are placed in a plasma treatment device and treated with oxygen or argon at a power of 100~200 W for 1~3 minutes.

[0040] The activated reinforcing fibers are immersed in a 0.5% to 2% silane coupling agent solution and stirred for 1 to 2 hours at a temperature of 60 to 80°C.

[0041] Modified reinforced fibers are obtained by vacuum drying at 80~100℃ for 2~4 hours.

[0042] Preferably, the nanofiller is obtained by modification through the following steps:

[0043] The nanofiller was dispersed in ethanol or water, and 0.5% to 1.0% of silane coupling agent was added. The mixture was stirred for 2 to 4 hours at a temperature of 60 to 80°C.

[0044] Add 0.1% to 0.5% of maleic anhydride by total mass of the solution and react for 1 to 2 hours;

[0045] After centrifugation, the nanofiller is vacuum dried at 80~100℃ for 2~4 hours to obtain the modified nanofiller.

[0046] The corrosion-resistant composite cable conductor prepared by the method provided by this invention has the following beneficial effects:

[0047] 1. The composite structure of the anti-creep reinforcement layer and the aluminum alloy conductor significantly improves the anti-creep capability of the cable under high temperature and long-term mechanical load, thus extending the service life of the cable.

[0048] 2. Aluminum alloy conductors are formed by optimizing the ratio of Si, Mg, Zn and conductivity-enhancing elements, combined with intermediate alloy smelting and aging treatment, to form a uniform strengthening phase that balances electrical conductivity and mechanical properties.

[0049] 3. The corrosion-resistant protective layer is tightly bonded to the composite cable through surface activation and secondary extrusion processes, making it suitable for humid or salt spray environments. Detailed Implementation

[0050] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be described in detail below. The description in this part is only exemplary and explanatory, and should not be used to limit the scope of protection of the present invention in any way.

[0051] This embodiment provides a method for preparing a corrosion-resistant composite cable conductor. The corrosion-resistant composite cable conductor includes, from the inside out, an aluminum alloy conductor, a creep-resistant reinforcing layer, and a corrosion-resistant protective layer, in weight percentages as follows:

[0052] The aluminum alloy conductor is made of the following components: Si 0.4%~0.6%, Fe 0.1%~0.3%, Cu 0~0.05%, Mg 0.4%~0.6%, Zn 0.05%~0.1%, conductivity-enhancing elements 0.01%~0.08%, and the balance being Al, wherein the content of impurity elements in the aluminum alloy conductor does not exceed 0.03%.

[0053] The creep-resistant reinforcing layer is made of the following components: 25%~40% reinforcing fiber, 58%~73% first polymer matrix, 0.5%~1.5% interface reinforcing agent, and 0.5%~2% nanofiller.

[0054] The corrosion-resistant protective layer is made of the following components: 89%~95% second polymer matrix, 0.5%~1.0% interface reinforcing agent, 2%~5% functional filler, and 3%~6% plasticizer.

[0055] The preparation method includes the following steps:

[0056] a. An aluminum alloy conductor mixture is prepared by melting, refining, casting, annealing, extruding and aging a high-purity aluminum matrix and an intermediate alloy containing conductivity-enhancing elements.

[0057] b. Prepare a creep-resistant reinforced mixture by mixing reinforcing fibers, polymer matrix, interface reinforcing agent and nanofiller according to weight percentage.

[0058] c. A composite cable containing an aluminum alloy conductor and an anti-creep reinforcement layer is prepared by co-extrusion of an aluminum alloy conductor mixture and an anti-creep reinforcement mixture.

[0059] d. The polymer matrix, interface reinforcing agent, functional filler and plasticizer are formulated and mixed according to weight percentage, and a corrosion-resistant protective layer is prepared on the outside of the composite cable through surface activation and secondary extrusion process.

[0060] The elements Si, Fe, Cu, Mg, and Zn can be included in the high-purity aluminum matrix, in the master alloy, or added to the mixture during the melting process (if applicable); the Si and Mg added to the aluminum alloy conductor can form Strengthening phases enhance strength; Zn assists in the formation of precipitates, improving mechanical properties; conductivity-enhancing elements react with impurity elements through intermediate alloy smelting to generate high-melting-point compounds, reducing the solid solubility of impurities in the aluminum matrix and decreasing lattice distortion, thereby improving conductivity; in terms of process, smelting, refining, casting, annealing, extrusion, and aging treatments optimize grain structure and precipitate distribution, ensuring a balance between high strength and high conductivity.

[0061] Reinforcing fibers (such as glass fiber and basalt fiber) provide high modulus and tensile strength, withstand external mechanical loads, and inhibit the creep deformation of aluminum alloys at high temperatures; interface reinforcing agents and nanofillers improve the interfacial bonding force between reinforcing fibers and the first polymer matrix, enhance interlayer mechanical transfer, and reduce the creep rate; and through a multi-layer co-extrusion process, the aluminum alloy conductor mixture and the creep-resistant reinforcing mixture are simultaneously molded to form a tightly bonded composite cable, ensuring the stability of creep resistance performance.

[0062] The second polymer matrix (polyvinyl chloride) provides good chemical stability, and functional fillers (such as nano-fillers) can also provide this. It can enhance weather resistance and UV resistance, plasticizer improves coating flexibility and prevents cracking; surface activation (such as plasma treatment or chemical coupling) can increase the chemical activity of the surface of the creep-resistant reinforcement layer, and the secondary extrusion process ensures a firm bond between the corrosion-resistant protective layer and the composite cable, forming a dense protective layer that effectively isolates water vapor, salt spray and corrosive ions.

[0063] The corrosion-resistant composite cable conductor prepared by the method described in this embodiment has the following beneficial effects:

[0064] 1. The composite structure of the anti-creep reinforcement layer and the aluminum alloy conductor significantly improves the anti-creep capability of the cable under high temperature and long-term mechanical load, thus extending the service life of the cable.

[0065] 2. Aluminum alloy conductors are formed by optimizing the ratio of Si, Mg, Zn and conductivity-enhancing elements, combined with intermediate alloy smelting and aging treatment, to form a uniform strengthening phase that balances electrical conductivity and mechanical properties.

[0066] 3. The corrosion-resistant protective layer is tightly bonded to the composite cable through surface activation and secondary extrusion processes, making it suitable for humid or salt spray environments.

[0067] Furthermore, the conductivity-enhancing elements include B, Zr, and rare earth elements, with the rare earth elements selected from at least one of Ce, L, and Y. The master alloys include Al-B, Al-Zr, and rare earth element alloys, with the rare earth element alloys selected from at least one of Al-Ce, Al-La, and Al-Y.

[0068] Among them, B can react with impurity elements such as Ti, V, Cr, and Mn to form high-melting-point borides (e.g., , This reduces the solid solubility of impurities in the aluminum matrix and decreases lattice scattering; Zr formation Precipitated phases optimize grain structure; rare earth elements (Ce, La, Y) react with Si and Fe to form Al-RE-Si and Al-RE-Fe compounds, further reducing the content of solid-solution impurities and improving electrical conductivity; rare earth elements reduce active sites on the aluminum alloy surface and inhibit electrochemical corrosion reactions by forming stable compounds; Al-B, Al-Zr, Al-Ce, Al-La, and Al-Y master alloys slowly release active elements during smelting to ensure uniform distribution and avoid volatilization or segregation caused by the addition of elemental elements.

[0069] Beneficially, by identifying B, Zr, and rare earth elements (Ce, La, Y) as the conductivity-enhancing elements, and using specific intermediate alloys (Al-B, Al-Zr, Al-Ce, Al-La, Al-Y), the solid solubility of impurity elements in aluminum alloy conductors is effectively reduced, resulting in higher stability. The introduction of rare earth elements further improves the electrochemical corrosion resistance of aluminum alloys and extends the service life of cables in humid or salt spray environments. Adding conductivity-enhancing elements in the form of intermediate alloys makes the melting process more uniform and reduces performance fluctuations caused by uneven element distribution.

[0070] Further, the reinforcing fiber is selected from at least one of glass fiber, basalt fiber, and carbon fiber. The first polymer matrix is ​​selected from at least one of polyamide, polypropylene, and polyetheretherketone. The interface reinforcing agent is selected from at least one of silane coupling agent, titanate coupling agent, and maleic anhydride grafted polymer. The nanofiller is selected from nano... ,nanometer ,nanometer At least one of the following. The second polymer matrix is ​​selected from at least one of polyvinyl chloride, polyethylene, and polyurethane. The functional filler is selected from nanomaterials. Nano ZnO, Nano At least one of the following. The plasticizer is selected from at least one of dioctyl phthalate, tributyl citrate, and epoxidized soybean oil.

[0071] Among them, glass fiber and basalt fiber provide high strength and low cost, while carbon fiber further improves modulus and creep resistance, jointly suppressing the deformation of aluminum alloys at high temperatures; polyamide (PA66) and polypropylene (PP) provide good heat resistance and chemical stability, while polyetheretherketone (PEEK) is suitable for extreme high-temperature environments; polyvinyl chloride (PVC), polyethylene (PE), and polyurethane (PU) serve as protective layer matrices, isolating external corrosive media; interface reinforcing agents improve the adhesion between fibers / fillers and the matrix through chemical bonding (such as the Si-O bonds of silane coupling agents); nanofillers ( , Increase the rigidity of the creep-resistant reinforcement layer, functional filler ( ZnO enhances weather resistance and UV protection, while plasticizers (DOP, TBC) improve coating flexibility.

[0072] Beneficially, by providing a variety of reinforcing fibers, polymer matrices, interface reinforcing agents, nanofillers, functional fillers, and plasticizers, it can meet the needs of different application scenarios, such as high-temperature or wear-resistant environments; through diversified component selection, the mechanical properties, weather resistance, and interlayer adhesion of the creep-resistant reinforcing layer and corrosion-resistant protective layer are significantly improved; low-cost materials (such as glass fiber, polyvinyl chloride) or high-performance materials (such as carbon fiber, polyetheretherketone) can be selected according to cost requirements to achieve a balance between performance and cost.

[0073] Furthermore, step a specifically includes the following sub-steps:

[0074] a1. Melt the high-purity aluminum matrix and the intermediate alloy containing conductivity-enhancing elements at 750~780℃ and hold for 20~40 minutes.

[0075] a2. Argon purging and The refining agent removes gases and inclusions, and the purging time is 10-15 minutes.

[0076] a3. Continuous casting to form aluminum alloy rods with a diameter of 10~15 mm, with a cooling rate of 10~15℃ / s.

[0077] Hold at 10-530℃ for 5-7 hours, then quickly water-cool to room temperature.

[0078] A5.440~490℃ is used to extrude an aluminum alloy conductor mixture with a diameter of 3~5 mm.

[0079] Keep warm at 170~210℃ for 6~10 hours.

[0080] Furthermore, step b specifically includes the following sub-steps:

[0081] b1. The reinforcing fibers, the first polymer matrix, the interface reinforcing agent and the nanofiller are mixed in weight percentage and granulated using a twin-screw extruder.

[0082] b2. Dry the mixture after batching at 80~120℃ for 2~4 hours to obtain the creep-resistant reinforced mixture.

[0083] Furthermore, step c specifically includes the following sub-steps:

[0084] c1. Micro-arc oxidation or chemical coupling treatment is applied to the surface of the aluminum alloy conductor mixture to form an oxide film or coupling layer.

[0085] c2. A composite cable containing an aluminum alloy conductor and an anti-creep reinforcement layer is prepared by simultaneously extruding an aluminum alloy conductor mixture and an anti-creep reinforcement mixture using a multi-layer co-extruder at an extrusion temperature of 180~380℃.

[0086] c3. Cool to room temperature with water.

[0087] Furthermore, step d specifically includes the following sub-steps:

[0088] d1. Mix the second polymer matrix, interface reinforcing agent, functional filler and plasticizer according to the weight percentage, and granulate using a single screw extruder.

[0089] d2. Perform plasma treatment or chemical coupling treatment on the surface of the creep-resistant reinforcement layer of the composite cable for 30-60 seconds.

[0090] d3. The mixture after batching is extruded onto the surface of the composite cable using a single screw extruder at an extrusion temperature of 160~210℃ to form a corrosion-resistant protective layer.

[0091] d4. Cool the air to room temperature.

[0092] Further, in step c1, the chemical coupling treatment specifically includes: immersing the aluminum alloy conductor mixture in a 1%~3% concentration silane coupling agent solution for 1~3 minutes, and drying it at 80~120℃ for 1~2 hours to form a silane coupling layer. In step d2, the chemical coupling treatment specifically includes: immersing the composite cable in a 1%~3% concentration titanate coupling agent solution for 30~60 seconds, and drying it at 80~120℃ for 1~2 hours to form a titanate coupling layer.

[0093] Among them, the silane coupling agent (KH-550 or KH-560) forms Si-O-Al bonds with the Al-OH on the aluminum alloy surface through Si-OH. A 1%~3% concentration and 1~3 minutes of immersion coating ensure uniform coverage. Drying at 80~120℃ forms a coupling layer, enhancing the bond between the aluminum alloy and the creep-resistant reinforcement layer. The titanate coupling agent (such as tetraisopropyl bis(dioctylphosphonic acid) titanate) reacts with the hydroxyl or carboxyl groups on the polymer matrix surface through Ti-O bonds. A 1%~3% concentration and 30~60 seconds of immersion coating form a coupling layer, enhancing the adhesion between the creep-resistant reinforcement layer and the corrosion-resistant protective layer. The two coupling agents form stable chemical bonds according to the chemical properties of different materials. The solvent is removed during the drying process to ensure the density of the coupling layer.

[0094] Furthermore, the reinforcing fibers are obtained through the following modifications:

[0095] The reinforcing fibers are ultrasonically cleaned in ethanol or acetone solution for 10-20 minutes to remove surface impurities.

[0096] Under an inert gas atmosphere, the cleaned reinforcing fibers are placed in a plasma treatment device and treated with oxygen or argon gas at a power of 100~200 W for 1~3 minutes.

[0097] The activated reinforcing fibers are immersed in a 0.5% to 2% silane coupling agent solution and stirred for 1 to 2 hours at a temperature of 60 to 80°C.

[0098] Modified reinforced fibers are obtained by vacuum drying at 80~100℃ for 2~4 hours.

[0099] Among them, ultrasonic cleaning with ethanol or acetone (20~40 kHz) can remove oil and impurities from the surface of the reinforcing fiber and increase surface cleanliness; oxygen or argon plasma treatment can introduce hydroxyl or carboxyl groups on the fiber surface and increase chemically active sites; 0.5%~2% silane coupling agent reacts with the fiber surface at 60~80℃ to form Si-OC or Si-O-Si bonds, which enhances the chemical bonding between the fiber and the polymer matrix; drying at 80~100℃ for 2~4 hours removes the solvent, ensuring the stability of the modified fiber for subsequent formulation and improving the mechanical properties of the creep-resistant reinforcing layer.

[0100] Beneficially, by modifying the reinforcing fibers, the interfacial bonding force between the fibers and the first polymer matrix can be significantly improved, the mechanical properties of the creep-resistant reinforcing layer are enhanced, and the creep rate is further reduced; the surface activity of the modified reinforcing fibers is improved, reducing fiber agglomeration and ensuring the uniformity of the creep-resistant reinforcing layer structure.

[0101] Furthermore, the nanofiller was obtained through the following modification steps:

[0102] The nanofiller is dispersed in ethanol or water, and 0.5% to 1.0% of silane coupling agent is added. The mixture is stirred for 2 to 4 hours at a temperature of 60 to 80°C.

[0103] Add 0.1% to 0.5% of maleic anhydride by total mass of the solution and react for 1 to 2 hours.

[0104] After centrifugation, the nanofiller is vacuum dried at 80~100℃ for 2~4 hours to obtain the modified nanofiller.

[0105] In this process, the nanofiller is dispersed in ethanol or water, and 0.5%~1.0% silane coupling agent reacts with the hydroxyl groups on the filler surface via Si-OH to form a chemically bonded layer; 0.1%~0.5% maleic anhydride reacts with the activated filler surface to form a grafted structure, further improving the compatibility between the filler and the polymer matrix; the solvent is removed by drying at 80~100℃ for 2~4 hours, and centrifugation is performed to ensure the purity of the filler. The modified filler is uniformly dispersed during the preparation process, enhancing the mechanical properties of the creep-resistant reinforcing layer.

[0106] Beneficially, the modified nanofiller can improve the rigidity and toughness of the creep-resistant reinforcement layer and enhance the synergistic effect between the fiber and the matrix; through functionalization modification with silane coupling agent and maleic anhydride, the compatibility between the nanofiller and the first polymer matrix is ​​improved and agglomeration is reduced.

[0107] Specific embodiments are provided below. These embodiments are intended to enable those skilled in the art to more fully understand the present invention, but do not limit the present invention in any way.

[0108] Example 1

[0109] 4980 g of high-purity aluminum matrix (99.90% purity), 20 g of Al-B master alloy (containing 5% B), 50 g of Al-Ce master alloy (containing 10% Ce), 250 g of Al-Mg master alloy (containing 10% Mg), 25 g of Si, 10 g of Fe, 1.5 g of Cu, and 3.5 g of Zn were placed in a medium-frequency induction melting furnace (500 kW power) and heated to 765℃. The mixture was held at this temperature for 30 minutes with a stirring speed of 200 rpm to ensure complete melting and uniform mixing, forming an aluminum alloy melt. At 765℃, the aluminum alloy melt was purged with argon gas for 12 minutes using an argon purging device (flow rate 10 L / min), while simultaneously adding 50 g of [unspecified ingredient]. A refining agent is added uniformly through a refining agent adder and stirred for 5 minutes to remove gases and inclusions from the melt, resulting in a refined aluminum alloy melt. The refined aluminum alloy melt is poured into a casting mold of a horizontal continuous casting machine and continuously cast at a cooling rate of 12.3℃ / s to form an aluminum alloy bar with a diameter of 12.0 mm. The aluminum alloy bar is placed in a box-type resistance furnace and held at 520℃ for 6 hours, followed by rapid water cooling to room temperature at a cooling rate of approximately 50℃ / s. The annealed aluminum alloy bar is placed in a hydraulic extruder, heated to 450℃, and extruded at an extrusion speed of 5 mm / s to form an aluminum alloy conductor mixture with a diameter of 4.0 mm. The extruded aluminum alloy conductor mixture is placed in an aging furnace and held at 190℃ for 8 hours, followed by natural cooling to room temperature to obtain the aluminum alloy conductor mixture.

[0110] 1500 g of glass fiber (3 mm in length), 3450 g of polyamide, 25 g of silane coupling agent (KH-550), and 25 g of nano- (Particle size 20 nm) was placed in a high-speed mixer and mixed at 500 rpm for 10 minutes to form a uniform creep-resistant reinforced mixture; the mixture was placed in a twin-screw extruder and extruded and granulated at 270°C and 200 rpm to form particles with a diameter of 2 mm; then dried in a vacuum drying oven at 100°C and 0.08 MPa for 3 hours to obtain the creep-resistant reinforced mixture.

[0111] The aluminum alloy conductor mixture was placed in a micro-arc oxidation device, using an electrolyte containing 10 g / L sodium silicate and 5 g / L sodium hydroxide, at a voltage of 400 V and a current density of 5. The mixture was processed for 10 minutes. The aluminum alloy conductor mixture (temperature 450℃) and the creep-resistant reinforcement mixture (extrusion temperature 270℃) were extruded simultaneously using a multi-layer co-extruder at an extrusion speed of 3 m / min to prepare a composite cable containing an aluminum alloy conductor with a diameter of 4.0 mm and a creep-resistant reinforcement layer with a thickness of 0.25 mm. The composite cable was then cooled to 25℃ at a cooling rate of approximately 20℃ / s in a water-cooling tank (length 5 m) to fix the composite cable structure.

[0112] 4750 g of polyvinyl chloride, 25 g of silane coupling agent (KH-550), and 100 g of nano- (Particle size 30 nm) and 125 g of dioctyl phthalate were placed in a high-speed mixer and mixed at 500 rpm for 8 minutes to form a uniform corrosion-resistant protective layer mixture. The mixture was then placed in a single-screw extruder and extruded and granulated at 190°C and 150 rpm to form particles with a diameter of 2 mm. The composite cable was placed in a plasma treatment machine using argon gas at a power of 120 W for 45 seconds. The corrosion-resistant protective layer mixture was then extruded onto the surface of the composite cable at 190°C using a single-screw extruder at an extrusion speed of 4 m / min to form a corrosion-resistant protective layer with a thickness of 0.15 mm. The composite cable was then cooled to 25°C using an air cooling device to cure the corrosion-resistant protective layer.

[0113] Using a polishing machine, polish the surface of the corrosion-resistant protective layer with 1000-grit sandpaper for 30 seconds to improve the surface smoothness and obtain the final cable conductor.

[0114] Tensile strength and elongation were tested using a universal tensile testing machine according to GB / T 228.1-2010 standard (specimen length 200 mm, tensile speed 5 mm / min); electrical conductivity was tested using a conductivity meter according to GB / T 12966-2008 standard (specimen length 1 m, 20℃); steady-state creep rate was tested for 24 hours at 120℃ and 50 MPa using a high-temperature creep tester (specimen length 100 mm); corrosion resistance was tested using a salt spray test chamber according to GB / T 10125-2012 standard (5% NaCl, 35℃, 120 hours). The test data are shown in Table 1 below.

[0115]

[0116] Example 2

[0117] 4980 g of high-purity aluminum matrix (99.90% purity), 20 g of Al-Zr master alloy (containing 5% Zr), 50 g of Al-La master alloy (containing 10% La), 250 g of Al-Mg master alloy (containing 10% Mg), 25 g of Si, 10 g of Fe, 1.5 g of Cu, and 3.5 g of Zn were placed in a medium-frequency induction melting furnace (500 kW power) and heated to 760℃. The mixture was held at this temperature for 32 minutes with a stirring speed of 200 rpm to ensure complete melting and uniform mixing, forming an aluminum alloy melt. At 760℃, the aluminum alloy melt was purged with argon gas (flow rate 10 L / min) for 13 minutes, while simultaneously adding 50 g of... A refining agent is added uniformly through a refining agent adder and stirred for 5 minutes to remove gases and inclusions from the melt, resulting in a refined aluminum alloy melt. The refined aluminum alloy melt is poured into a casting mold of a horizontal continuous casting machine and continuously cast at a cooling rate of 12.5℃ / s to form an aluminum alloy bar with a diameter of 12.0 mm. The aluminum alloy bar is placed in a box-type resistance furnace and held at 515℃ for 6.5 hours, followed by rapid water cooling to room temperature at a cooling rate of approximately 50℃ / s. The annealed aluminum alloy bar is placed in a hydraulic extruder, heated to 460℃, and extruded at an extrusion speed of 5 mm / s to form an aluminum alloy conductor mixture with a diameter of 4.0 mm. The extruded aluminum alloy conductor mixture is placed in an aging furnace and held at 195℃ for 7.5 hours, followed by natural cooling to room temperature to obtain the aluminum alloy conductor mixture.

[0118] 1500 g of basalt fiber (3 mm in length), 3450 g of polypropylene, 25 g of titanate coupling agent (tetraisopropyl bis(dioctylphosphonic acid) titanate), and 25 g of nano- (Particle size 25 nm) was placed in a high-speed mixer and mixed at 500 rpm for 10 minutes to form a uniform creep-resistant reinforced mixture; the mixture was placed in a twin-screw extruder and extruded and granulated at 190°C and 200 rpm to form particles with a diameter of 2 mm; then dried in a vacuum drying oven at 90°C and 0.08 MPa for 3.5 hours to obtain the creep-resistant reinforced mixture.

[0119] The aluminum alloy conductor mixture was placed in a chemical coupling treatment tank and immersed in a 2% concentration of silane coupling agent (KH-560) solution for 2 minutes, followed by drying in a vacuum drying oven at 100°C for 1.5 hours. The aluminum alloy conductor mixture (temperature 460°C) and the creep-resistant reinforcement mixture (extrusion temperature 190°C) were simultaneously extruded using a multi-layer co-extruder at an extrusion speed of 3 m / min to prepare a composite cable containing an aluminum alloy conductor with a diameter of 4.0 mm and a creep-resistant reinforcement layer with a thickness of 0.25 mm. The composite cable was then cooled to 25°C in a water-cooling tank (length 5 m) at a cooling rate of approximately 20°C / s to fix the composite cable structure.

[0120] 4750 g of polyethylene, 25 g of titanate coupling agent (tetraisopropyl bis(dioctylphosphonic acid) titanate), 100 g of nano ZnO (particle size 30 nm) and 125 g of tributyl citrate were placed in a high-speed mixer and mixed at 500 rpm for 8 minutes. The mixture was then placed in a single-screw extruder and extruded and granulated at 170°C and 150 rpm to form particles with a diameter of 2 mm. The composite cable was placed in a plasma treatment machine using oxygen at a power of 130 W for 40 seconds. The corrosion-resistant protective layer mixture was then extruded onto the surface of the composite cable at 170°C and 4 m / min using a single-screw extruder to form a corrosion-resistant protective layer. The composite cable was then cooled to 25°C using an air cooling device to cure the corrosion-resistant protective layer.

[0121] Using a polishing machine, polish the surface of the corrosion-resistant protective layer with 1000-grit sandpaper for 30 seconds to improve the surface smoothness and obtain the final cable conductor.

[0122] The test items and methods are the same as in Example 1, and the test data are shown in Table 2 below:

[0123]

[0124] Example 3

[0125] 4980 g of high-purity aluminum matrix (99.90% purity), 15 g of Al-B master alloy (containing 5% B), 15 g of Al-Zr master alloy (containing 5% Zr), 25 g of Al-Ce master alloy (containing 10% Ce), 25 g of Al-La master alloy (containing 10% La), 250 g of Al-Mg master alloy (containing 10% Mg), 25 g of Si, 10 g of Fe, 1.5 g of Cu, and 3.5 g of Zn were placed in a medium-frequency induction melting furnace (500 kW) and heated to 762℃. The mixture was held at this temperature for 31 minutes with a stirring speed of 200 rpm to ensure complete melting and uniform mixing, forming an aluminum alloy melt. At 762℃, the aluminum alloy melt was purged with argon gas for 12.5 minutes using an argon purging device (flow rate 10 L / min), while simultaneously adding 50 g of [unspecified ingredient]. A refining agent is added uniformly through a refining agent adder and stirred for 5 minutes to remove gases and inclusions from the melt, resulting in a refined aluminum alloy melt. The refined aluminum alloy melt is poured into a casting mold of a horizontal continuous casting machine and continuously cast at a cooling rate of 12.4℃ / s to form an aluminum alloy bar with a diameter of 12.0 mm. The aluminum alloy bar is placed in a box-type resistance furnace and held at 518℃ for 6.2 hours, followed by rapid water cooling to room temperature at a cooling rate of approximately 50℃ / s. The annealed aluminum alloy bar is placed in a hydraulic extruder, heated to 455℃, and extruded at an extrusion speed of 5 mm / s to form an aluminum alloy conductor mixture with a diameter of 4.0 mm. The extruded aluminum alloy conductor mixture is placed in an aging furnace and held at 192℃ for 7.8 hours, followed by natural cooling to room temperature to obtain the aluminum alloy conductor mixture.

[0126] The following ingredients were combined: 750 g glass fiber (3 mm in length), 750 g basalt fiber (3 mm in length), 1725 g polyamide, 1725 g polypropylene, 15 g silane coupling agent (KH-550), 10 g titanate coupling agent (tetraisopropyl bis(dioctylphosphonic acid) titanate), and 15 g nano- (Particle size 20 nm) and 10 g nanoparticles (Particle size 25 nm) was placed in a high-speed mixer and mixed at 500 rpm for 10 minutes to form a uniform creep-resistant reinforced mixture; the mixture was placed in a twin-screw extruder and extruded and granulated at 230°C and 200 rpm to form particles with a diameter of 2 mm; then dried in a vacuum drying oven at 95°C and 0.08 MPa for 3.2 hours to obtain the creep-resistant reinforced mixture.

[0127] The aluminum alloy conductor mixture was placed in a chemical coupling treatment tank and immersed in a 2% concentration of silane coupling agent (KH-560) solution for 2 minutes, followed by drying in a vacuum drying oven at 100°C for 1.5 hours. The aluminum alloy conductor mixture (temperature 455°C) and the creep-resistant reinforcement mixture (extrusion temperature 230°C) were simultaneously extruded using a multi-layer co-extruder at an extrusion speed of 3 m / min to prepare a composite cable containing an aluminum alloy conductor with a diameter of 4.0 mm and a creep-resistant reinforcement layer with a thickness of 0.25 mm. The composite cable was then cooled to 25°C in a water-cooling tank (length 5 m) at a cooling rate of approximately 20°C / s to fix the composite cable structure.

[0128] 2375 g of polyvinyl chloride, 2375 g of polyethylene, 15 g of silane coupling agent (KH-550), 10 g of titanate coupling agent (tetraisopropyl bis(dioctylphosphite) titanate), and 50 g of nano- 50 g of nano-ZnO (30 nm particle size), 75 g of dioctyl phthalate, and 50 g of tributyl citrate were placed in a high-speed mixer and mixed at 500 rpm for 8 minutes to form a uniform corrosion-resistant protective layer mixture. The mixture was then placed in a single-screw extruder and extruded at 180°C and 150 rpm to form particles with a diameter of 2 mm. The composite cable was placed in a plasma treatment machine using oxygen at a power of 125 W for 42 seconds. The corrosion-resistant protective layer mixture was then extruded onto the surface of the composite cable at 180°C using a single-screw extruder at an extrusion speed of 4 m / min to form a corrosion-resistant protective layer. The composite cable was then cooled to 25°C using an air cooling device to cure the corrosion-resistant protective layer.

[0129] Using a polishing machine, polish the surface of the corrosion-resistant protective layer with 1000-grit sandpaper for 30 seconds to improve the surface smoothness and obtain the final cable conductor.

[0130] The test items and methods are the same as in Example 1, and the test data are shown in Table 3 below:

[0131]

[0132] Example 4

[0133] 4980 g of high-purity aluminum matrix (99.90% purity), 20 g of Al-B master alloy (containing 5% B), 50 g of Al-Ce master alloy (containing 10% Ce), 250 g of Al-Mg master alloy (containing 10% Mg), 25 g of Si, 10 g of Fe, 1.5 g of Cu, and 3.5 g of Zn were placed in a medium-frequency induction melting furnace (500 kW power) and heated to 765℃. The mixture was held at this temperature for 30 minutes with a stirring speed of 200 rpm to ensure complete melting and uniform mixing, forming an aluminum alloy melt. At 765℃, the aluminum alloy melt was purged with argon gas for 12 minutes using an argon purging device (flow rate 10 L / min), while simultaneously adding 50 g of [unspecified ingredient]. A refining agent is added uniformly through a refining agent adder and stirred for 5 minutes to remove gases and inclusions from the melt, resulting in a refined aluminum alloy melt. The refined aluminum alloy melt is poured into a casting mold of a horizontal continuous casting machine and continuously cast at a cooling rate of 12.3℃ / s to form an aluminum alloy bar with a diameter of 12.0 mm. The aluminum alloy bar is placed in a box-type resistance furnace and held at 520℃ for 6 hours, followed by rapid water cooling to room temperature at a cooling rate of approximately 50℃ / s. The annealed aluminum alloy bar is placed in a hydraulic extruder, heated to 450℃, and extruded at an extrusion speed of 5 mm / s to form an aluminum alloy conductor mixture with a diameter of 4.0 mm. The extruded aluminum alloy conductor mixture is placed in an aging furnace and held at 190℃ for 8 hours, followed by natural cooling to room temperature to obtain the aluminum alloy conductor mixture.

[0134] 1500 g of glass fiber (3 mm in length) was placed in 5000 mL of ethanol solution and cleaned using an ultrasonic cleaner (40 kHz frequency) for 15 minutes to remove surface impurities. It was then dried in a vacuum drying oven at 80 °C for 2 hours. The cleaned glass fiber was then placed in a plasma treatment machine and treated with oxygen at 150 W for 2 minutes to increase the hydroxyl groups on the fiber surface. The activated glass fiber was then immersed in 5000 mL of 1% silane coupling agent (KH-550) solution and stirred with a magnetic stirrer at 70 °C for 1.5 hours to form a surface graft layer. The modified glass fiber was then dried in a vacuum drying oven at 90 °C and a vacuum degree of 0.08 MPa for 3 hours to obtain modified glass fiber. 1500 g of modified glass fiber, 3450 g of polyamide, 25 g of silane coupling agent (KH-550), and 25 g of nano-... (Particle size 20 nm) was placed in a high-speed mixer and mixed at 500 rpm for 10 minutes to form a uniform creep-resistant reinforced mixture; the mixture was placed in a twin-screw extruder and extruded and granulated at 270°C and 200 rpm to form particles with a diameter of 2 mm; then dried in a vacuum drying oven at 100°C and 0.08 MPa for 3 hours to obtain the creep-resistant reinforced mixture.

[0135] The aluminum alloy conductor mixture was placed in a micro-arc oxidation device, using an electrolyte containing 10 g / L sodium silicate and 5 g / L sodium hydroxide, at a voltage of 400 V and a current density of 5. The mixture was processed for 10 minutes. The aluminum alloy conductor mixture (temperature 450℃) and the creep-resistant reinforcement mixture (extrusion temperature 270℃) were extruded simultaneously using a multi-layer co-extruder at an extrusion speed of 3 m / min to prepare a composite cable containing an aluminum alloy conductor with a diameter of 4.0 mm and a creep-resistant reinforcement layer with a thickness of 0.25 mm. The composite cable was then cooled to 25℃ at a cooling rate of approximately 20℃ / s in a water-cooling tank (length 5 m) to fix the composite cable structure.

[0136] 4750 g of polyvinyl chloride, 25 g of silane coupling agent (KH-550), and 100 g of nano- (Particle size 30 nm) and 125 g of dioctyl phthalate were placed in a high-speed mixer and mixed at 500 rpm for 8 minutes to form a uniform corrosion-resistant protective layer mixture. The mixture was then placed in a single-screw extruder and extruded and granulated at 190°C and 150 rpm to form particles with a diameter of 2 mm. The composite cable was placed in a plasma treatment machine using argon gas at a power of 120 W for 45 seconds. The corrosion-resistant protective layer mixture was then extruded onto the surface of the composite cable at 190°C using a single-screw extruder at an extrusion speed of 4 m / min to form a corrosion-resistant protective layer. The composite cable was then cooled to 25°C using an air cooling device to cure the corrosion-resistant protective layer.

[0137] Using a polishing machine, polish the surface of the corrosion-resistant protective layer with 1000-grit sandpaper for 30 seconds to improve the surface smoothness and obtain the final cable conductor.

[0138] The test items and methods are the same as in Example 1, and the test data are shown in Table 4 below:

[0139]

[0140] Example 5

[0141] 4980 g of high-purity aluminum matrix (99.90% purity), 20 g of Al-B master alloy (containing 5% B), 50 g of Al-Ce master alloy (containing 10% Ce), 250 g of Al-Mg master alloy (containing 10% Mg), 25 g of Si, 10 g of Fe, 1.5 g of Cu, and 3.5 g of Zn were placed in a medium-frequency induction melting furnace (500 kW power) and heated to 765℃. The mixture was held at this temperature for 30 minutes with a stirring speed of 200 rpm to ensure complete melting and uniform mixing, forming an aluminum alloy melt. At 765℃, the aluminum alloy melt was purged with argon gas for 12 minutes using an argon purging device (flow rate 10 L / min), while simultaneously adding 50 g of [unspecified ingredient]. A refining agent is added uniformly through a refining agent adder and stirred for 5 minutes to remove gases and inclusions from the melt, resulting in a refined aluminum alloy melt. The refined aluminum alloy melt is poured into a casting mold of a horizontal continuous casting machine and continuously cast at a cooling rate of 12.3℃ / s to form an aluminum alloy bar with a diameter of 12.0 mm. The aluminum alloy bar is placed in a box-type resistance furnace and held at 520℃ for 6 hours, followed by rapid water cooling to room temperature at a cooling rate of approximately 50℃ / s. The annealed aluminum alloy bar is placed in a hydraulic extruder, heated to 450℃, and extruded at an extrusion speed of 5 mm / s to form an aluminum alloy conductor mixture with a diameter of 4.0 mm. The extruded aluminum alloy conductor mixture is placed in an aging furnace and held at 190℃ for 8 hours, followed by natural cooling to room temperature to obtain the aluminum alloy conductor mixture.

[0142] 25 g nano (Particle size 20 nm) was dispersed in 500 mL of ethanol, and 0.2 g of silane coupling agent (KH-550) was added. The mixture was stirred at 70 °C for 3 hours using a magnetic stirrer to form activated nanofiller. 0.1 g of maleic anhydride was added to the activated nanofiller, and the mixture was stirred at 70 °C for 1.5 hours to form surface-grafted nanofiller. The functionalized nanofiller was centrifuged (4000 rpm) for 5 minutes, and then dried in a vacuum drying oven at 90 °C and 0.08 MPa for 3 hours to obtain modified nanofiller. ; 1500 g glass fiber (3 mm in length), 3450 g polyamide, 25 g silane coupling agent (KH-550) and 25 g modified nano The mixture was placed in a high-speed mixer and mixed at 500 rpm for 10 minutes to form a uniform creep-resistant reinforced mixture. The mixture was then placed in a twin-screw extruder and extruded and granulated at 270°C and 200 rpm to form particles with a diameter of 2 mm. Subsequently, the particles were dried in a vacuum drying oven at 100°C and 0.08 MPa for 3 hours to obtain the creep-resistant reinforced mixture.

[0143] The aluminum alloy conductor mixture was placed in a micro-arc oxidation device, using an electrolyte containing 10 g / L sodium silicate and 5 g / L sodium hydroxide, at a voltage of 400 V and a current density of 5. The mixture was processed for 10 minutes. The aluminum alloy conductor mixture (temperature 450℃) and the creep-resistant reinforcement mixture (extrusion temperature 270℃) were extruded simultaneously using a multi-layer co-extruder at an extrusion speed of 3 m / min to prepare a composite cable containing an aluminum alloy conductor with a diameter of 4.0 mm and a creep-resistant reinforcement layer with a thickness of 0.25 mm. The composite cable was then cooled to 25℃ at a cooling rate of approximately 20℃ / s in a water-cooling tank (length 5 m) to fix the composite cable structure.

[0144] 4750 g of polyvinyl chloride, 25 g of silane coupling agent (KH-550), and 100 g of nano- (Particle size 30 nm) and 125 g of dioctyl phthalate were placed in a high-speed mixer and mixed at 500 rpm for 8 minutes to form a uniform corrosion-resistant protective layer mixture. The mixture was then placed in a single-screw extruder and extruded and granulated at 190°C and 150 rpm to form particles with a diameter of 2 mm. The composite cable was placed in a plasma treatment machine and treated with argon gas at a power of 120 W for 45 seconds to increase the chemical activity of the surface of the creep-resistant reinforcing layer. The corrosion-resistant protective layer mixture was then extruded onto the surface of the composite cable at 190°C using a single-screw extruder at an extrusion speed of 4 m / min to form a corrosion-resistant protective layer. The composite cable was then cooled to 25°C using an air cooling device to cure the corrosion-resistant protective layer.

[0145] Using a polishing machine, polish the surface of the corrosion-resistant protective layer with 1000-grit sandpaper for 30 seconds to improve the surface smoothness and obtain the final cable conductor.

[0146] The test items and methods are the same as in Example 1, and the test data are shown in Table 5 below:

[0147]

[0148] Comparative Example 1

[0149] 4980 g of high-purity aluminum matrix (99.90% purity), 20 g of Al-B master alloy (containing 5% B), 50 g of Al-Ce master alloy (containing 10% Ce), 250 g of Al-Mg master alloy (containing 10% Mg), 25 g of Si, 10 g of Fe, 1.5 g of Cu, and 3.5 g of Zn were placed in a medium-frequency induction melting furnace (500 kW power) and heated to 765℃. The mixture was held at this temperature for 30 minutes with a stirring speed of 200 rpm to ensure complete melting and uniform mixing, forming an aluminum alloy melt. At 765℃, the aluminum alloy melt was purged with argon gas for 12 minutes using an argon purging device (flow rate 10 L / min), while simultaneously adding 50 g of [unspecified ingredient]. A refining agent is added uniformly through a refining agent adder and stirred for 5 minutes to remove gases and inclusions from the melt, resulting in a refined aluminum alloy melt. The refined aluminum alloy melt is poured into a casting mold of a horizontal continuous casting machine and continuously cast at a cooling rate of 12.3℃ / s to form an aluminum alloy rod with a diameter of 12.0 mm. The aluminum alloy rod is placed in a box-type resistance furnace and held at 520℃ for 6 hours, followed by rapid water cooling to room temperature at a cooling rate of approximately 50℃ / s. The annealed aluminum alloy rod is placed in a hydraulic extrusion press, heated to 450℃, and extruded at an extrusion speed of 5 mm / s to form an aluminum alloy conductor with a diameter of 4.0 mm. The extruded aluminum alloy conductor is placed in an aging furnace and held at 190℃ for 8 hours, followed by natural cooling to room temperature to obtain an aluminum alloy cable conductor. The surface of the aluminum alloy conductor is polished for 30 seconds with 1000-grit sandpaper using a polishing machine to improve the surface finish, resulting in the final aluminum alloy cable conductor.

[0150] The test items and methods are the same as in Example 1, and the test data are shown in Table 6 below:

[0151]

[0152] Comparative Example 2

[0153] 4980 g of high-purity aluminum matrix (99.90% purity), 20 g of Al-B master alloy (containing 5% B), 50 g of Al-Ce master alloy (containing 10% Ce), 250 g of Al-Mg master alloy (containing 10% Mg), 25 g of Si, 10 g of Fe, 1.5 g of Cu, and 3.5 g of Zn were placed in a medium-frequency induction melting furnace (500 kW power) and heated to 765℃. The mixture was held at this temperature for 30 minutes with a stirring speed of 200 rpm to ensure complete melting and uniform mixing, forming an aluminum alloy melt. At 765℃, the aluminum alloy melt was purged with argon gas for 12 minutes using an argon purging device (flow rate 10 L / min), while simultaneously adding 50 g of [unspecified ingredient]. A refining agent is added uniformly through a refining agent adder and stirred for 5 minutes to remove gases and inclusions from the melt, resulting in a refined aluminum alloy melt. The refined aluminum alloy melt is poured into a casting mold of a horizontal continuous casting machine and continuously cast at a cooling rate of 12.3℃ / s to form an aluminum alloy bar with a diameter of 12.0 mm. The aluminum alloy bar is placed in a box-type resistance furnace and held at 520℃ for 6 hours, followed by rapid water cooling to room temperature at a cooling rate of approximately 50℃ / s. The annealed aluminum alloy bar is placed in a hydraulic extruder, heated to 450℃, and extruded at an extrusion speed of 5 mm / s to form an aluminum alloy conductor mixture with a diameter of 4.0 mm. The extruded aluminum alloy conductor mixture is placed in an aging furnace and held at 190℃ for 8 hours, followed by natural cooling to room temperature to obtain the aluminum alloy conductor mixture.

[0154] 1500 g of glass fiber (3 mm in length) and 3500 g of polyamide were placed in a high-speed mixer and mixed at 500 rpm for 10 minutes to form a uniform creep-resistant reinforced mixture. The mixture was then placed in a twin-screw extruder and extruded and granulated at 270°C and 200 rpm to form particles with a diameter of 2 mm. Subsequently, the particles were dried in a vacuum drying oven at 100°C and 0.08 MPa for 3 hours to obtain the creep-resistant reinforced mixture.

[0155] The aluminum alloy conductor mixture was placed in a micro-arc oxidation device, using an electrolyte containing 10 g / L sodium silicate and 5 g / L sodium hydroxide, at a voltage of 400 V and a current density of 5. The mixture was processed for 10 minutes. The aluminum alloy conductor mixture (temperature 450℃) and the creep-resistant reinforcement mixture (extrusion temperature 270℃) were extruded simultaneously using a multi-layer co-extruder at an extrusion speed of 3 m / min to prepare a composite cable containing an aluminum alloy conductor with a diameter of 4.0 mm and a creep-resistant reinforcement layer with a thickness of 0.25 mm. The composite cable was then cooled to 25℃ at a cooling rate of approximately 20℃ / s in a water-cooling tank (length 5 m) to fix the composite cable structure.

[0156] 4975 g of polyvinyl chloride and 25 g of silane coupling agent (KH-550) were placed in a high-speed mixer and mixed at 500 rpm for 8 minutes to form a uniform corrosion-resistant protective layer mixture. The mixture was then placed in a single-screw extruder and extruded at 190°C and 150 rpm to form granules with a diameter of 2 mm. The composite cable was placed in a plasma treatment machine using argon gas at a power of 120 W for 45 seconds to increase the chemical activity of the surface of the creep-resistant reinforcing layer. The corrosion-resistant protective layer mixture was then extruded onto the surface of the composite cable at 190°C using a single-screw extruder at an extrusion speed of 4 m / min to form a corrosion-resistant protective layer with a thickness of 0.15 mm. The composite cable was then cooled to 25°C using an air cooling device to cure the corrosion-resistant protective layer.

[0157] Using a polishing machine, polish the surface of the corrosion-resistant protective layer with 1000-grit sandpaper for 30 seconds to improve the surface smoothness and obtain the final cable conductor.

[0158] The test items and methods are the same as in Example 1, and the test data are shown in Table 7 below:

[0159]

[0160] Comparative Example 3

[0161] 5030 g of high-purity aluminum matrix (99.90% purity), 250 g of Al-Mg master alloy (containing 10% Mg), 25 g of Si, 10 g of Fe, 1.5 g of Cu, and 3.5 g of Zn were placed in a medium-frequency induction melting furnace (500 kW) and heated to 765°C. The mixture was held at this temperature for 30 minutes with a stirring speed of 200 rpm to ensure complete melting and uniform mixing, forming an aluminum alloy melt. At 765°C, the aluminum alloy melt was purged with argon gas (10 L / min) for 12 minutes, while simultaneously adding 50 g of [unspecified ingredient]. A refining agent is added uniformly through a refining agent adder and stirred for 5 minutes to remove gases and inclusions from the melt, resulting in a refined aluminum alloy melt. The refined aluminum alloy melt is poured into a casting mold of a horizontal continuous casting machine and continuously cast at a cooling rate of 12.3℃ / s to form an aluminum alloy bar with a diameter of 12.0 mm. The aluminum alloy bar is placed in a box-type resistance furnace and held at 520℃ for 6 hours, followed by rapid water cooling to room temperature at a cooling rate of approximately 50℃ / s. The annealed aluminum alloy bar is placed in a hydraulic extruder, heated to 450℃, and extruded at an extrusion speed of 5 mm / s to form an aluminum alloy conductor mixture with a diameter of 4.0 mm. The extruded aluminum alloy conductor mixture is placed in an aging furnace and held at 190℃ for 8 hours, followed by natural cooling to room temperature to obtain the aluminum alloy conductor mixture.

[0162] 1500 g of glass fiber (3 mm in length), 3450 g of polyamide, 25 g of silane coupling agent (KH-550), and 25 g of nano- (Particle size 20 nm) was placed in a high-speed mixer and mixed at 500 rpm for 10 minutes to form a uniform creep-resistant reinforced mixture; the mixture was placed in a twin-screw extruder and extruded and granulated at 270°C and 200 rpm to form particles with a diameter of 2 mm; then dried in a vacuum drying oven at 100°C and 0.08 MPa for 3 hours to obtain the creep-resistant reinforced mixture.

[0163] The aluminum alloy conductor mixture was placed in a micro-arc oxidation device, using an electrolyte containing 10 g / L sodium silicate and 5 g / L sodium hydroxide, at a voltage of 400 V and a current density of 5. The mixture was processed for 10 minutes. The aluminum alloy conductor mixture (temperature 450℃) and the creep-resistant reinforcement mixture (extrusion temperature 270℃) were extruded simultaneously using a multi-layer co-extruder at an extrusion speed of 3 m / min to prepare a composite cable containing an aluminum alloy conductor with a diameter of 4.0 mm and a creep-resistant reinforcement layer with a thickness of 0.25 mm. The composite cable was then cooled to 25℃ at a cooling rate of approximately 20℃ / s in a water-cooling tank (length 5 m) to fix the composite cable structure.

[0164] 4875 g of polyvinyl chloride, 25 g of silane coupling agent (KH-550), and 100 g of dioctyl phthalate were placed in a high-speed mixer and mixed at 500 rpm for 8 minutes to form a uniform corrosion-resistant protective layer mixture. The mixture was then placed in a single-screw extruder and extruded at 190°C and 150 rpm to form granules with a diameter of 2 mm. The composite cable was then placed in a plasma treatment machine using argon gas at a power of 120 W for 45 seconds to increase the chemical activity of the surface of the creep-resistant reinforcing layer. The corrosion-resistant protective layer mixture was then extruded onto the surface of the composite cable at 190°C using a single-screw extruder at an extrusion speed of 4 m / min to form a corrosion-resistant protective layer with a thickness of 0.15 mm. The composite cable was then cooled to 25°C using an air cooling device to cure the corrosion-resistant protective layer.

[0165] Using a polishing machine, polish the surface of the corrosion-resistant protective layer with 1000-grit sandpaper for 30 seconds to improve the surface smoothness and obtain the final cable conductor.

[0166] The test items and methods are the same as in Example 1, and the test data are shown in Table 8 below:

[0167]

[0168] The data above shows that:

[0169] The tensile strengths of Examples 1-5 ranged from 330.5 to 348.3 MPa, all meeting the requirement of ≥330 MPa. Examples 4 (348.3 MPa) and 5 (342.1 MPa) showed the best performance, due to the modified glass fiber (Example 4) and modified nanofibers. (Example 5) Enhanced the interfacial bonding force of the creep-resistant layer, improving mechanical properties. Example 3 (335.2 MPa) used multiple components (B, Zr, Ce, La, and glass fiber, basalt fiber, etc.), and its synergistic effect was slightly better than that of Example 1 (332.5 MPa) and Example 2 (330.5 MPa), which used single components. Comparative Example 1 (305.6 MPa) lacked a creep-resistant reinforcement layer and a corrosion-resistant protective layer, relying solely on the aluminum alloy conductor, resulting in significantly lower strength than required, illustrating the crucial role of the composite structure in tensile strength. Comparative Example 2 (325.4 MPa) lacked the nano-materials in the creep-resistant reinforcement layer. The presence of KH-550 resulted in insufficient bonding between the fiber and the PA66 matrix, leading to substandard strength. Comparative Example 3 (328.9 MPa) lacked B and Ce, resulting in grain refinement and... The formation of the reinforcing phase is limited, and the strength is slightly lower than required.

[0170] Examples 1-5 showed elongation rates ranging from 8.1% to 8.8%, all meeting the requirement of ≥8.0%. Examples 4 (8.8%) and 5 (8.7%) showed higher elongation rates, indicating that modified fibers and nanofillers improved the material's toughness. Comparative Example 1 (9.1%) lacked a composite layer; the aluminum alloy exhibited high toughness but insufficient strength, resulting in a higher elongation rate. Comparative Examples 2 and 3 (8.2% and 8.3%) retained the creep-resistant reinforcement layer, exhibiting moderate toughness and meeting the requirements.

[0171] Examples 1-5 exhibited conductivity ranging from 53.4% ​​to 53.9% IACS, all meeting the requirement of ≥53% IACS. Example 3 (53.9%) showed the highest conductivity due to the synergistic optimization of the lattice structure by multiple conductivity-enhancing elements (B, Zr, Ce, La), which reduced electron scattering. Comparative Examples 1 and 2 (53.7% and 53.6%) retained B and Ce, achieving conductivity levels close to those of Example 1. Comparative Example 3 (52.8%) lacked B and Ce, resulting in substandard conductivity, demonstrating the significant impact of conductivity-enhancing elements on electrical conductivity.

[0172] The steady-state creep rate in Examples 1-5 is 4.6 × ~ 4.8× All satisfy ≤5.0× Comparative Example 1 (7.2 × The lack of a creep-resistant reinforcement layer resulted in excessive creep rate, making the aluminum alloy prone to deformation under high temperature and high stress. Comparative Example 2 (6.1× (lack of nanotechnology) Compared to KH-550, the fiber-matrix interfacial bonding is weak, and the creep rate exceeds the standard. Comparative Example 3 (5.0× The complete anti-creep reinforcement layer is retained, and the creep rate meets the standard, but is slightly higher than that of Example 1, because the lack of B and Ce affects the grain stability.

[0173] Examples 1-5 showed no significant corrosion during the 120-hour salt spray test due to the corrosion-resistant protective layer (containing...). (e.g., DOP) provides excellent corrosion resistance. Comparative Example 1 lacks a protective layer and shows slight pitting corrosion after 120 hours, indicating that the aluminum alloy surface is susceptible to corrosion. Comparative Example 2 lacks... With DOP, the protective layer lacked sufficient weather resistance, resulting in minor pitting corrosion. Comparative Example 3 lacked... DOP is retained, and the corrosion resistance is slightly better than that of Comparative Example 2, but a small amount of pitting corrosion still occurs.

[0174] In summary, Examples 4 and 5 exhibit the best performance due to the optimized mechanical properties of the anti-creep layer achieved by the modified fibers and nanofillers. Example 3 demonstrates excellent overall performance, with the synergistic effect of multiple components improving conductivity and dimensional accuracy, making it suitable for applications requiring high conductivity and stability. Comparative Examples 1-3 show that the absence of an anti-creep reinforcement layer, a corrosion-resistant protective layer, or key components leads to a significant performance degradation, validating the necessity of composite structures and functional components.

[0175] This article uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the technical scope disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be within the scope of protection of the present invention.

Claims

1. A method for preparing a corrosion-resistant composite cable conductor, characterized in that, The corrosion-resistant composite cable conductor comprises, from the inside out, an aluminum alloy conductor, a creep-resistant reinforcing layer, and a corrosion-resistant protective layer, in weight percentage as follows: The aluminum alloy conductor is made of the following components: Si 0.4%~0.6%, Fe 0.1%~0.3%, Cu 0~0.05%, Mg 0.4%~0.6%, Zn 0.05%~0.1%, conductivity-enhancing elements 0.01%~0.08%, and the balance being Al. The impurity element content in the aluminum alloy conductor does not exceed 0.03%, and the conductivity-enhancing elements include B, Zr, and rare earth elements, wherein the rare earth elements are selected from at least one of Ce, L, and Y. The creep-resistant reinforcing layer is composed of the following components: 25%~40% reinforcing fibers, 58%~73% first polymer matrix, 0.5%~1.5% interface reinforcing agent, and 0.5%~2% nanofiller; The corrosion-resistant protective layer is composed of the following components: 89%~95% second polymer matrix, 0.5%~1.0% interface reinforcing agent, 2%~5% functional filler, and 3%~6% plasticizer; The preparation method includes the following steps: a) An aluminum alloy conductor mixture is prepared by smelting, refining, casting, annealing, extruding, and aging a high-purity aluminum matrix and an intermediate alloy containing conductivity-enhancing elements. The specific steps include the following: a1. Melt a high-purity aluminum matrix and an intermediate alloy containing conductivity-enhancing elements at 750~780℃ and hold for 20~40 minutes, wherein the intermediate alloy includes Al-B, Al-Zr and rare earth element alloys, and the rare earth element alloys are selected from at least one of Al-Ce, Al-La and Al-Y. a2. Argon purging and The refining agent removes gases and inclusions; the purging time is 10-15 minutes. a3. Continuous casting to form aluminum alloy bars with a diameter of 10~15 mm, with a cooling rate of 10~15℃ / s; a4.510~530℃ for 5~7 hours, then rapidly water-cooled to room temperature; a5.440~490℃ extrusion to form an aluminum alloy conductor mixture with a diameter of 3~5 mm; a6.170~210℃ for 6~10 hours; b) The reinforcing fibers, polymer matrix, interface reinforcing agent and nanofiller are formulated and mixed according to weight percentages to obtain a creep-resistant reinforcing mixture; c) The aluminum alloy conductor mixture and the creep-resistant reinforcement mixture are co-extruded to prepare a composite cable containing an aluminum alloy conductor and a creep-resistant reinforcement layer; d) The polymer matrix, interface reinforcing agent, functional filler and plasticizer are formulated and mixed according to weight percentage, and a corrosion-resistant protective layer is prepared on the outside of the composite cable through surface activation and secondary extrusion process.

2. The method for preparing corrosion-resistant composite cable conductor according to claim 1, characterized in that: The reinforcing fiber is selected from at least one of glass fiber, basalt fiber, and carbon fiber; The first polymer matrix is ​​selected from at least one of polyamide, polypropylene, and polyetheretherketone; The interface enhancer is selected from at least one of silane coupling agents, titanate coupling agents, and maleic anhydride graft polymers. The nanofiller is selected from nanomaterials. ,nanometer ,nanometer At least one of them; The second polymer matrix is ​​selected from at least one of polyvinyl chloride, polyethylene, and polyurethane; The functional filler is selected from nanomaterials. Nano ZnO, Nano At least one of them; The plasticizer is selected from at least one of dioctyl phthalate, tributyl citrate, and epoxidized soybean oil.

3. The method for preparing corrosion-resistant composite cable conductor according to any one of claims 1 to 2, characterized in that, Step b specifically includes the following sub-steps: b1. Mix the reinforcing fiber, the first polymer matrix, the interface reinforcing agent and the nanofiller according to the weight percentage, and granulate them using a twin-screw extruder; b2. Dry the mixture after batching at 80~120℃ for 2~4 hours to obtain the creep-resistant reinforced mixture.

4. The method for preparing corrosion-resistant composite cable conductor according to any one of claims 1 to 2, characterized in that, Step c specifically includes the following sub-steps: c1. Micro-arc oxidation or chemical coupling treatment is applied to the surface of aluminum alloy conductor mixture to form an oxide film or coupling layer; c2. A composite cable containing an aluminum alloy conductor and an anti-creep reinforcement layer is prepared by simultaneously extruding an aluminum alloy conductor mixture and an anti-creep reinforcement mixture using a multi-layer co-extruder at an extrusion temperature of 180~380℃. c3. Cool to room temperature with water.

5. The method for preparing corrosion-resistant composite cable conductor according to claim 4, characterized in that, Step d specifically includes the following sub-steps: d1. Mix the second polymer matrix, interface reinforcing agent, functional filler and plasticizer according to the weight percentage, and granulate using a single screw extruder; d2. Perform plasma treatment or chemical coupling treatment on the surface of the creep-resistant reinforcement layer of the composite cable for 30-60 seconds; d3. The mixture after batching is extruded onto the surface of the composite cable using a single screw extruder at an extrusion temperature of 160~210℃ to form a corrosion-resistant protective layer; d4. Cool the air to room temperature.

6. The method for preparing corrosion-resistant composite cable conductor according to claim 5, characterized in that: In step c1, the chemical coupling treatment specifically includes: immersing the aluminum alloy conductor mixture in a 1% to 3% concentration silane coupling agent solution for 1 to 3 minutes, and drying it at 80 to 120°C for 1 to 2 hours to form a silane coupling layer; In step d2, the chemical coupling treatment specifically includes: immersing the composite cable in a 1%~3% concentration titanate coupling agent solution for 30~60 seconds, and drying it at 80~120℃ for 1~2 hours to form a titanate coupling layer.

7. The method for preparing corrosion-resistant composite cable conductor according to any one of claims 1 to 2, characterized in that, The reinforcing fiber is obtained by the following steps: The reinforcing fibers are ultrasonically cleaned in ethanol or acetone solution for 10-20 minutes to remove surface impurities. Under an inert gas atmosphere, the cleaned reinforcing fibers are placed in a plasma treatment device and treated with oxygen or argon at a power of 100~200 W for 1~3 minutes. The activated reinforcing fibers are immersed in a 0.5% to 2% silane coupling agent solution and stirred for 1 to 2 hours at a temperature of 60 to 80°C. Modified reinforced fibers are obtained by vacuum drying at 80~100℃ for 2~4 hours.

8. The method for preparing corrosion-resistant composite cable conductor according to any one of claims 1 to 2, characterized in that, The nanofiller was obtained by modification through the following steps: The nanofiller was dispersed in ethanol or water, and 0.5% to 1.0% of silane coupling agent was added. The mixture was stirred for 2 to 4 hours at a temperature of 60 to 80°C. Add 0.1% to 0.5% of maleic anhydride by total mass of the solution and react for 1 to 2 hours; After centrifugation, the nanofiller is vacuum dried at 80~100℃ for 2~4 hours to obtain the modified nanofiller.

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