High-temperature-resistant and mechanical-impact-resistant super-flexible composite cable special for smelting equipment

Abstract

The invention discloses a high-temperature-resistant and mechanical-impact-resistant super-flexible composite cable special for smelting equipment. The high-temperature-resistant and mechanical-impact-resistant super-flexible composite cable comprises a conductor part, a shielding layer, a sheath layer, a protective layer and an armor layer. The conductor part is additionally provided with a central reinforcing core on the basis of the wire, the overall tensile property is improved through the axial reinforcing design, and meanwhile, the filling wire is arranged to reduce the friction coefficient in the conductor part and reduce the wear rate of the wire; through the multi-layer design of the wire insulating layer, the shielding layer, the sheath layer, the protective layer and the armor layer, the tensile property, the electromagnetic shielding property, the high temperature resistance and the fireproof property are improved. Therefore, the high-temperature-resistant and mechanical-impact-resistant super-flexible composite cable special for the smelting equipment has the advantages of being high in mechanical stress resistance, high in environmental adaptability and stable in performance.

Description

Technical Field

[0001] This invention relates to a cable, and more particularly to a high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment, characterized by high resistance to mechanical stress, strong environmental adaptability, and stable performance. Background Technology

[0002] High-temperature smelting equipment operates in a high-temperature and high-vibration environment. Therefore, cables used in high-temperature smelting equipment must meet the following performance indicators: High temperature resistance: The cable must withstand instantaneous high temperatures of 500℃~1200℃ (near the electrode area); Mechanical stress resistance: It must withstand equipment vibration frequencies ≥50Hz, and its tensile strength must be >15N / mm²; Chemical resistance: It must resist corrosion from slags such as FeO and SiO2, as well as acid gas erosion; Fire resistance: It must pass the IEC 60331-2 fire resistance test (950℃ / 3h continuous power supply); Electromagnetic shielding: The double-layer shielding structure meets the EN 50288-7 standard.

[0003] Currently, cables for high-temperature smelting equipment mainly adopt a traditional XLPE insulation + single-layer metal shield + steel tape armor structure design, which has significant technical limitations in terms of adaptability to ultra-high temperature environments: the traditional XLPE insulation layer is prone to softening in environments above 50°C, which cannot meet the requirements of ultra-high temperature (such as above 300°C) conditions often encountered around smelting furnaces, resulting in rapid decay of insulation performance; at the same time, the mechanical strength of the existing structure decreases significantly at high temperatures, and vibration fatigue and thermal cycling can easily cause micro-cracks in the insulation layer. Furthermore, there is a lack of special oxidation-resistant and corrosion-resistant materials designed for ultra-high temperature environments, making it difficult to adapt to the complex working conditions of long-term high temperature, dust, and strong impact in smelting furnaces.

[0004] Therefore, it is necessary to propose an improvement to overcome the shortcomings of the existing technology. Summary of the Invention

[0005] The purpose of this invention is to solve the problems in the prior art and provide a high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment, which has high resistance to mechanical stress, strong environmental adaptability, and stable performance.

[0006] The technical solution of this invention is: A high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment includes a conductor, a shielding layer, a sheath, a protective layer, and an armor layer. The conductor includes a conductor, a central reinforcing core, and filler wires. The conductor includes a core and an insulation layer covering the core. A central reinforcing core is located at the center of the conductor, and multiple filler wires are arranged around the core and the conductor. The shielding layer is disposed on the outside of the conductor and includes an aluminum-plastic composite layer and a tin-plated copper braided layer. The sheath is disposed on the outside of the shielding layer and is made of ceramicized silicone material. The protective layer is disposed on the outside of the sheath and is made of glass fiber braided material. The armor layer is disposed on the outside of the protective layer and is made of galvanized steel wire braided material.

[0007] As a preferred technical solution, the conductor includes multiple conductors with different functions and specifications.

[0008] As a preferred technical solution, the core is formed by stranding 0.1mm ultrafine monofilament conductors.

[0009] As a further preferred technical solution, the ultrafine monofilament conductor is a type 6 nickel-plated copper conductor conforming to the IEC 60228 standard.

[0010] As a preferred technical solution, the insulation layer includes ceramicized silicone rubber near the wire core and fluororubber disposed outside the ceramicized silicone rubber.

[0011] As a preferred technical solution, the breaking tensile strength of the central reinforcing core is ≥18kN.

[0012] As a preferred technical solution, the central reinforcing core is a galvanized steel wire rope with a diameter of 0.25mm.

[0013] As a preferred technical solution, the filler thread is a composite fiber paper rope formed by combining aramid fiber and basalt fiber; the axial tensile strength of the composite fiber paper rope is ≥800MPa and the temperature resistance range is -196℃~650℃.

[0014] As a preferred technical solution, the sheath layer is 2.4mm thick, has an oxygen index ≥45, a temperature resistance range of -40℃ to 260℃, and a heat shrinkage rate ≤2%.

[0015] As a preferred technical solution, the armor layer is 0.15mm thick.

[0016] This invention discloses a high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable specifically designed for smelting equipment. The conductor portion incorporates a central reinforcing core on top of the existing conductor, and its axial reinforcement design enhances overall tensile strength. Additionally, filler wires are incorporated to reduce the internal friction coefficient of the conductor, minimizing conductor wear. The multi-layered design, consisting of an insulation layer, shielding layer, sheathing layer, protective layer, and armor layer, improves tensile strength, electromagnetic shielding performance, high-temperature resistance, and fire resistance. Therefore, this high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment possesses advantages such as high resistance to mechanical stress, strong environmental adaptability, and stable performance. Attached Figure Description

[0017] Figure 1 This is a cross-sectional view of a specific embodiment of the high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment according to the present invention. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] The terminology used in the embodiments of this invention is for the purpose of describing particular embodiments only and is not intended to limit the invention. The singular forms “a,” “the,” and “the” used in the embodiments of this invention and the appended claims are also intended to include the plural forms, unless the context clearly indicates otherwise. “Multiple” generally includes at least two, but does not exclude the inclusion of at least one.

[0020] It should be understood that the term "and / or" used in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this article generally indicates that the preceding and following related objects have an "or" relationship.

[0021] Depending on the context, the words “if” or “suppose” as used here can be interpreted as “when” or “in response to determination” or “in response to detection.” Similarly, depending on the context, the phrases “if determination” or “if detection (of the stated condition or event)” can be interpreted as “when determination” or “in response to determination” or “when detection (of the stated condition or event)” or “in response to detection (of the stated condition or event).”

[0022] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a product or system comprising a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a product or system. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the product or system that includes said element.

[0023] like Figure 1 The diagram illustrates a specific embodiment of the high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment according to the present invention. This embodiment of the high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment includes a conductor portion, a shielding layer, a sheath layer 3, a protective layer 4, and an armor layer 5. Specifically: The conductor portion includes a conductor, a central reinforcing core 12, and filler wires 13. The conductor includes a core 11a and an insulating layer covering the core 11a. The central reinforcing core 12 is located at the center of the conductor portion, and multiple filler wires 13 are arranged around the central reinforcing core 12 and the conductor shaft. In specific implementations, multiple conductors with different functions and specifications can be provided as needed. Figure 1 As shown in this embodiment, a high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment is a 6X10+4X25+4.0 mm² composite cable. Specifically, in this embodiment, six 10mm² cores are used for power transmission and grounding protection, and four 2.5mm² cores are used for power transmission and grounding protection in the dynamic control system. The central reinforcing core 12 is 4.0 mm². In this embodiment, all conductor cores 11a are formed by stranding 0.1mm ultra-fine monofilament conductors. These ultra-fine monofilament conductors are Category 6 nickel-plated copper conductors conforming to IEC 60228 standards. Specifically, the 10mm² conductor structure is 1273 / 0.10mm, 2.5mm²... 2The conductor structure is 319 / 0.10mm. In this embodiment, the conductor core 11a adopts a 0.10mm ultra-fine monofilament stranded structure. The creep-resistant conductor formed by the multi-strand layered stranding process reduces the overall bending radius to 4D (cable diameter). It can still achieve 180° repeated bending (≥5000 cycles) without cracking in a low temperature environment of -40℃, improving the adaptability of laying in confined spaces. In this embodiment, the insulation layer includes ceramicized silicone rubber 11b near the conductor core and fluororubber 11c disposed outside the ceramicized silicone rubber. The ceramicized silicone rubber 11b has ceramicized sintering characteristics at high temperature, forming an insulating ceramic shell in a fire environment; the fluororubber 11c provides long-term temperature resistance of -40℃~260℃ and oil corrosion resistance. In this embodiment, the breaking tensile strength of the central reinforcing core 12 is ≥18kN. It adopts galvanized steel wire rope with a diameter of 0.25mm (equivalent cross-sectional area of ​​4.0mm²), and the overall tensile strength is improved by the central axial reinforcement design. In this embodiment, the filler wire 13 is a composite fiber paper rope formed by combining aramid fiber and basalt fiber; the composite fiber paper rope has an axial tensile strength ≥800MPa and a temperature resistance range of -196℃ to 650℃. The composite fiber paper rope formed by combining aramid fiber and basalt fiber in the filler wire 13 has a density of 0.8g / cm³, an oxygen index ≥38, and achieves a structural roundness error ≤2% through a gradient density filling process. The filler wire 13 has the properties of an axial tensile strength ≥800MPa and a temperature resistance range of -196℃ to 650℃. Under a bending radius of 4D, it can reduce the friction coefficient between core wires to 0.15, reducing the core wire wear rate by 60% compared to traditional PP filler materials. At the same time, through the fiber interlacing structure, it absorbs vibration energy and improves the fatigue resistance of the cable by 30%.

[0024] A shielding layer is disposed on the outside of the conductor portion. The shielding layer includes an aluminum-plastic composite layer 21 and a tin-plated copper braided layer 22. The aluminum-plastic composite layer 21 is disposed close to the conductor portion, and the tin-plated copper braided layer 22 is disposed on the outside of the aluminum-plastic composite layer 21. The shielding layer features a dual shielding structure consisting of an aluminum-plastic composite layer 21 and a tin-plated copper braided layer 22, forming an electromagnetic barrier with a coverage rate of over 92%. This structure ensures that the crosstalk loss of the high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment is ≤55dB at a frequency of 1MHz, guaranteeing that the power transmission and control system signals are not subject to external electromagnetic interference. Compared to a single-layer shielding structure, the mechanical strength is increased by 40%, and the overall tensile and impact resistance of the cable is further enhanced by the central reinforcing core 12. At the same time, the metal layer and braided layer of the aluminum-plastic composite layer 21 form a synergistic protection, raising the waterproof rating to IPX6, effectively blocking the intrusion of dust, moisture, and corrosive liquids in the smelting environment, and protecting the internal insulation layer and core. The tin-plated copper braided layer 22 enhances the high-temperature oxidation resistance, and the temperature resistance of the aluminum-plastic composite layer 21 is suitable for operating conditions of -40℃ to 260℃. Together with the conductor insulation layer and sheath layer 3, they form a protective system resistant to extreme environments.

[0025] The sheath layer 3 is disposed on the outside of the shielding layer and is made of ceramicized silicone material. The sheath layer 3 is 2.4mm thick, has an oxygen index ≥45, a temperature resistance range of -40℃ to 260℃, and a heat shrinkage rate ≤2%. In this embodiment, the high flame retardant properties and combustion ceramicization properties of the sheath layer 3 (oxygen index ≥45) together with the ceramicized silicone rubber 11b of the conductor insulation layer near the core 11a form a double fire barrier, ensuring the insulation integrity under high temperature and fire conditions; with a temperature resistance range of -40℃ to 260℃ and a heat shrinkage rate of ≤2%, it adapts to the extreme temperature fluctuations of the smelting environment; the 2.4mm extruded layer provides mechanical protection against friction, scratching, and slag corrosion; and in conjunction with the armor layer 5, it forms a rigid-flexible protection system that balances impact resistance and vibration buffering capacity, improving the overall reliability of the cable under complex smelting conditions.

[0026] The protective layer 4 is wrapped around the outside of the sheath layer 3, and is a glass fiber braided protective layer. The protective layer 4, using a glass fiber braided protective layer, achieves multiple protective functions through material properties and structural design: With a wide temperature tolerance range of -196℃ to 650℃, it forms a gradient temperature resistance system with the ceramicized silicone rubber 11b and fluororubber 11c of the conductor insulation layer, adapting to ultra-high temperature conditions in smelting environments and improving overall heat resistance stability; utilizing the mechanical buffering characteristics of the braided structure, it absorbs vibration energy and reduces friction between core wires, and, together with the central reinforcing core 12 and the armor layer 5, improves fatigue resistance and reduces insulation wear during bending installation; through high insulation characteristics (volume resistivity > 10¹), it achieves multiple protective functions. 4 The Ω·cm) auxiliary reinforcement enhances the cable insulation strength and works with the shielding layer to ensure electrical safety; the chemical stability blocks the corrosion of acidic gases and slag dust, and together with fluororubber 11c, it forms a multi-layer anti-corrosion barrier; the tightly wrapped structure helps maintain the roundness of the cable cross section (error ≤2%), ensuring that the core wire does not misalign under the bending radius 4D working condition, and together with the filler wire 13, it improves the structural stability.

[0027] The armor layer 5 is wrapped around the outside of the protective layer 4. The armor layer 5 is a galvanized steel wire braided layer. In this embodiment, the armor layer 5 is 0.15mm thick. The 0.15mm galvanized steel wire braided layer, through a high-strength galvanized steel wire braided structure, works in conjunction with the galvanized steel wire rope reinforcement of the central reinforcing core 12 to improve the overall tensile strength (breaking force ≥18kN), resisting the vibration (frequency ≥50Hz) of smelting equipment and mechanical impact. The metal braided layer of the armor layer 5 and the aluminum-plastic composite layer 21 of the shielding layer form a double protection, improving the resistance to compression and wear, and working with the glass fiber braided layer of the protective layer 4 to reduce core wire wear. The galvanizing treatment enhances corrosion resistance and, together with the fluororubber 11c and nickel-plated wire core, forms an anti-corrosion system to block the corrosion of slag and acidic gases.

[0028] This embodiment presents a high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable specifically designed for smelting equipment, featuring a multi-structure synergistic design: The conductor core 11a and the central reinforcing core 12 in the conductor section are designed in tandem. The conductor core 11a is a 0.10mm ultra-fine monofilament nickel-plated copper conductor stranded in the IEC 60228 standard, which improves high-temperature oxidation resistance and flexibility. The bending radius is reduced to 4D, and it can withstand repeated 180° bending (≥5000 times) at a low temperature of -40℃ without cracking. The central reinforcing core 12 is a 43 / 0.25mm galvanized steel wire rope (breaking strength ≥18kN). The axial reinforcement design improves the overall tensile strength and solves the problems of creep resistance and laying in confined spaces in traditional cables.

[0029] The conductor features a multi-layered insulation and protective layer design: the insulation layer is a double-layer composite design, with an inner layer of ceramicized silicone rubber 11b and an outer layer of fluororubber 11c. The ceramicized silicone rubber 11b is ceramicized at high temperature to form an insulating shell, while the outer layer provides long-term temperature resistance from -40℃ to 260℃ and resistance to oil corrosion. The glass fiber braided layer of the protective layer 4 (wide temperature resistance from -196℃ to 650℃) works in conjunction with the gradient temperature resistance system (inner ceramicized silicone rubber 11b + outer fluororubber 11c) to achieve ultra-high temperature adaptability and mechanical buffering, reducing the core wire friction coefficient to 0.15.

[0030] The shielding layer and armor layer are designed in synergy. The shielding layer includes an aluminum-plastic composite layer 21 and a tin-plated copper braided layer 22, forming an electromagnetic barrier with a coverage of over 92%. The crosstalk loss at 1MHz is ≤55dB, and the waterproof rating reaches IPX6, blocking dust, water vapor, and corrosive liquids. The armor layer 5 has a 0.15mm galvanized steel wire braided structure, which, together with the central reinforcement, improves tensile strength (breaking force ≥18kN), resists vibration and mechanical impact at ≥50Hz, and the galvanizing treatment enhances corrosion resistance.

[0031] Compared with ordinary cables, the high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment in this embodiment has achieved breakthroughs in high-temperature resistance and fire resistance: it solves the problem of softening of traditional XLPE insulation layer above 50°C, and achieves instantaneous high-temperature resistance of 500°C to 1200°C through the protective layer 4 of ceramicized silicone rubber 11b + glass fiber braided layer, meeting the IEC60331-2 fire resistance test (950°C / 3h continuous power supply), filling the gap in ultra-high temperature working conditions of smelting furnaces.

[0032] This embodiment of a high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment has the following technical advantages: 1. Enhanced resistance to mechanical stress and flexibility: The ultra-flexible conductor structure (4D bending radius) and central reinforced core design result in a tensile strength >15N / mm², a breaking strength ≥18kN, and resistance to equipment vibration and mechanical impact at ≥50Hz. Compared with traditional cables, its fatigue resistance is improved by 30%, and the core wire wear rate is reduced by 60%. 2. Enhanced chemical corrosion and environmental adaptability: The nickel-plated copper conductor, fluororubber outer layer, zinc-plated armor layer, and glass fiber protective layer work together to form multiple anti-corrosion barriers, effectively resisting the erosion of FeO, SiO2 slag, and acidic gases. The temperature resistance range covers -40℃ to 650℃, adapting to dusty and high-impact complex environments. 3. Electromagnetic compatibility and structural stability optimization: The double-layer shielding structure meets the EN 50288-7 standard, with crosstalk loss ≤55dB at 1MHz, ensuring uninterrupted power and control signal transmission; the gradient filling and tight wrapping design ensures a cross-sectional roundness error of ≤2%, preventing core wire misalignment under bending conditions and improving laying reliability. 4. Improved construction and maintenance efficiency: The multi-core composite structure (6X10+4X2.5+4.0mm²) integrates power, control, and grounding functions, reducing the traditional splitting and wiring process of multiple independent cables, lowering construction time by 60%, saving laying space, and significantly improving maintenance convenience.

[0033] This invention discloses a high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable specifically designed for smelting equipment. The conductor section incorporates a central reinforcing core on top of the existing conductor, enhancing overall tensile strength through axial reinforcement. Filler wires are also included to reduce the internal friction coefficient of the conductor, minimizing conductor wear. A multi-layered design, comprising insulation, shielding, sheathing, protective, and armor layers, further improves tensile strength, electromagnetic shielding, high-temperature resistance, and fire resistance. This high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment, through material innovation (nickel-plated copper conductor, ceramicized silicone rubber, etc.) and structural synergy (central reinforcing core-filler wire-shielding layer-armor layer design), comprehensively overcomes the technical bottlenecks of traditional smelting cables in terms of high-temperature resistance, mechanical impact resistance, corrosion resistance, and flexibility, achieving safe and stable operation in extreme environments. Therefore, this high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment possesses advantages such as high mechanical stress resistance, strong environmental adaptability, and stable performance.

[0034] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the invention. All equivalent changes and modifications made in accordance with the scope of the claims of this invention should fall within the technical scope of this invention.

Claims

1. A high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for special use in smelting equipment, characterized in that: Includes the conductor layer, shielding layer, sheath layer, protective layer, and armor layer; The conductor portion includes a conductor, a central reinforcing core, and filler wires; the conductor includes a wire core and an insulating layer covering the wire core, the conductor portion has a central reinforcing core at its center, and the central reinforcing core and the conductor are surrounded by multiple filler wires. The shielding layer is disposed on the outside of the conductor portion, and the shielding layer includes an aluminum-plastic composite layer and a tin-plated copper braided layer; The sheath layer is disposed on the outside of the shielding layer, and the sheath layer is made of ceramicized silicone material; The protective layer is disposed on the outside of the sheath layer, and the protective layer is a glass fiber woven protective layer; The armor layer is disposed on the outside of the protective layer, and the armor layer is a galvanized steel wire braided layer.

2. The high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment according to claim 1, characterized in that: The conductors include multiple conductors with different functions and specifications.

3. The high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment according to claim 1, characterized in that: The core is formed by twisting together 0.1mm ultra-fine monofilament conductors.

4. The high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment according to claim 3, characterized in that: The ultra-fine monofilament conductor is a type 6 nickel-plated copper conductor conforming to the IEC 60228 standard.

5. The high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment according to claim 1, characterized in that: The insulation layer includes ceramicized silicone rubber near the wire core and fluororubber disposed outside the ceramicized silicone rubber.

6. The high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment according to claim 1, characterized in that: The breaking tensile strength of the central reinforcing core is ≥18kN.

7. The high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment according to claim 1, characterized in that: The central reinforcing core is a galvanized steel wire rope with a diameter of 0.25mm.

8. The high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment according to claim 1, characterized in that: The filler thread is a composite fiber paper rope formed by combining aramid fiber and basalt fiber; the axial tensile strength of the composite fiber paper rope is ≥800MPa and the temperature resistance range is -196℃~650℃.

9. The high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment according to claim 1, characterized in that: The sheath layer is 2.4mm thick, has an oxygen index ≥45, a temperature resistance range of -40℃ to 260℃, and a heat shrinkage rate ≤2%.

10. The high-temperature resistant and mechanically impact-resistant ultra-flexible composite cable for smelting equipment according to claim 1, characterized in that: The armor layer is 0.15 mm thick.

Images