High-temperature-resistant anti-corrosion cable

Abstract

The invention relates to the technical field of wires and cables, and discloses a high-temperature-resistant anti-corrosion cable which comprises a conductor core, an insulating layer, a shielding layer, an anti-corrosion layer and a high-temperature-resistant sheath layer which are sequentially arranged from inside to outside. The insulating layer is made of an insulating composite material, the anti-corrosion layer is formed by coating and curing an anti-corrosion coating, and the high-temperature-resistant sheath layer is made of a high-temperature-resistant sheath material; the matrix resin adopted by the insulating layer, the high-temperature-resistant modifier and the insulating reinforcing filler are subjected to melt blending to form a compact composite material system, and the nanoscale high-temperature-resistant modifier is uniformly dispersed in the matrix resin, so that thermal motion of a macromolecular chain is hindered, and a stable protective barrier is formed at high temperature; the thermal deformation resistance and the insulation stability of the material are improved; meanwhile, the insulation reinforcing filler and the resin matrix form firm interface bonding and act together, the migration path of internal electrons is blocked, and the insulation performance and the long-term reliability of the cable are improved.

Description

Technical Field

[0001] This invention relates to the field of wire and cable technology, specifically to a high-temperature resistant and corrosion-resistant cable. Background Technology

[0002] In recent years, the global wire and cable market has become increasingly mature. With the rapid development of my country's economy, the demand for high-temperature cables in special industries has entered a stage of rapid growth. As an important component of special cables, high-temperature cables have strong vitality and are in short supply. High-temperature cables are special cables made of multi-strand soft copper conductors, using fluoroplastics or silicone rubber as insulation layers, and filled with glass fiber.

[0003] Currently, in the manufacturing and application of high-temperature and corrosion-resistant cables, due to the long-term exposure to complex working conditions involving high temperatures, corrosive media, or alternating conditions of both, the cable's key protective layers, including the insulation layer, corrosion-resistant layer, and sheath layer, are prone to polymer chain degradation, filler interface failure, and coating cracking and peeling under the combined effects of thermo-oxidative aging, chemical media penetration, and mechanical stress. This leads to irreversible degradation of their insulation and corrosion-resistant properties, making it difficult to guarantee long-term reliability within the design life.

[0004] Therefore, a high-temperature resistant and corrosion-resistant cable is proposed to solve the above problems. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a high-temperature resistant and corrosion-resistant cable that solves the problems mentioned in the background art, such as polymer chain degradation, filler interface failure, and coating cracking and peeling, which make it difficult to guarantee long-term reliability within the design life.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a high-temperature resistant and corrosion-resistant cable, the cable comprising, from the inside out, a conductor core, an insulation layer, a shielding layer, a corrosion-resistant layer, and a high-temperature resistant sheath layer; The insulating layer is made of an insulating composite material, which includes the following raw materials in parts by weight: 100-120 parts of matrix resin, 20-30 parts of high-temperature resistant modifier, 15-25 parts of insulating reinforcing filler, 3-8 parts of compatibilizer, 1-3 parts of antioxidant and 1-2 parts of lubricant. The anti-corrosion layer is formed by coating and curing an anti-corrosion coating, which comprises the following raw materials in parts by weight: 80-100 parts of anti-corrosion resin matrix, 10-20 parts of flake anti-corrosion filler, 5-10 parts of nano anti-corrosion additive, 10-15 parts of curing agent, 30-50 parts of solvent and 2-5 parts of additive. The high-temperature resistant sheath layer is made of a high-temperature resistant sheath material, which includes the following raw materials in parts by weight: 100-150 parts of high-temperature resistant polymer, 25-40 parts of synergistic heat resistant agent, 10-20 parts of reinforcing fiber, 5-10 parts of processing aid, and 2-4 parts of color masterbatch.

[0007] Preferably, the conductor core is a conductive wire core made of multiple tin-plated copper wires or silver-plated copper wires twisted together, the cross-sectional area of ​​the conductive wire core is 1.5-95mm², the thickness of the insulation layer is 0.8-2.0mm, the thickness of the anti-corrosion layer is 0.2-0.5mm, and the thickness of the high-temperature resistant sheath layer is 1.5-3.0mm. The matrix resin is at least one of ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer and polyolefin elastomer, and the high-temperature resistant modifier is a mixture of at least two of nano-magnesium oxide, nano-alumina and nano-boron nitride that have been surface treated with silane coupling agent, with a particle size range of 30-100 nm. The insulating reinforcing filler is at least one of calcined kaolin, precipitated barium sulfate, and silica powder, with a particle size range of 1-10 μm. The compatibilizer is maleic anhydride-grafted polyolefin. The antioxidant is a compound of pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] and tris[2,4-di-tert-butylphenyl] phosphite, with a compound weight ratio of 1:1 to 1:2. The lubricant is at least one of zinc stearate, polyethylene wax, and ethylene bis-stearamide.

[0008] Preferably, the method for preparing the insulating composite material includes the following steps: The matrix resin is dried in an oven at 80-100°C for 2-4 hours until its moisture content is below 0.05%. The dried matrix resin, the high-temperature resistant modifier, the insulating reinforcing filler, the compatibilizer, the antioxidant, and the lubricant are added to a high-speed mixer according to the weight ratio described above, and mixed at a speed of 500-800 r / min for 5-10 minutes to obtain a premix. The premixed material is fed into a twin-screw extruder for melt blending, extrusion, and granulation. The temperatures of each section of the extruder are set as follows: Zone 1 150-160℃, Zone 2 165-175℃, Zone 3 170-180℃, Zone 4 175-185℃, Die head temperature 180-190℃, and screw speed 200-300 r / min. After being cooled in a water tank, the extruded strip is cut into uniform particles by a pelletizer to obtain the insulating composite material.

[0009] Preferably, the anti-corrosion resin matrix is ​​at least one of epoxy resin, modified epoxy resin and phenolic epoxy resin, and the sheet-like anti-corrosion filler is at least one of surface-activated mica powder, glass flakes and aluminum powder, with a sheet diameter of 200-800 mesh and a thickness of 1-5 μm. The nano-corrosion inhibitor is at least one of nano-titanium dioxide, nano-zinc oxide, and nano-montmorillonite treated with plasma, with a particle size range of 20-80 nm. The curing agent is at least one of polyamide curing agents, modified amine curing agents, and phenolic amine curing agents. The solvent is a mixed solvent composed of xylene, n-butanol, and cyclohexanone in a weight ratio of 3:1:1. The additives include leveling agents, defoamers, and thixotropic agents. The leveling agent is a polyacrylate leveling agent, the defoamer is an organosilicon defoamer, and the thixotropic agent is fumed silica.

[0010] Preferably, the method for preparing the anti-corrosion coating includes the following steps: Step 1: Add the anticorrosive resin matrix and part of the solvent into a dispersion vessel, and disperse at a stirring speed of 300-500 r / min for 10-15 minutes to obtain a resin solution; Step 2: After drying the sheet-like anti-corrosion filler and nano-anti-corrosion additive at 100-120℃ for 1-2 hours, add them and the remaining solvent into a ball mill, use zirconia balls as the grinding medium, the ball-to-material ratio is 5:1-10:1, and ball mill at a speed of 200-400 r / min for 2-4 hours to obtain the filler slurry. Step 3: Mix the obtained resin solution with the obtained filler slurry, add it to the dispersion vessel, and disperse it at a high-speed dispersion rate of 800-1200 r / min for 30-60 minutes; Step 4: Transfer the evenly dispersed mixture into a grinding device for grinding until the fineness reaches below 20μm; Step 5: Add the curing agent and additives to the ground material, and stir at a low speed of 400-600 r / min for 15-30 minutes to avoid introducing too many air bubbles, so as to obtain a uniform anti-corrosion coating.

[0011] Preferably, the high-temperature resistant polymer is at least one of polyetheretherketone, polyphenylene sulfide, and thermoplastic polyimide, and the synergistic heat resistant agent is a mixture of at least two of nano-silicon carbide, boron phenolic resin, and organosilicon-modified acrylate resin. The reinforcing fiber is at least one of chopped glass fiber, basalt fiber and carbon fiber treated with silane coupling agent, and the fiber length is 3-6 mm. The processing aids include heat stabilizer and lubricant. The heat stabilizer is a compound of hindered phenols and phosphites. The lubricant is at least one of pentaerythritol stearate and lignite wax ester. The color masterbatch is a high-temperature resistant inorganic pigment coloring masterbatch.

[0012] Preferably, the method for preparing the high-temperature resistant sheath material includes the following steps: Step 1: Dry the high-temperature resistant polymer in a vacuum oven at 120-150℃ for 3-6 hours until its moisture content is below 0.02%; Step 2: Add the dried high-temperature resistant polymer, the synergistic heat resistant agent, reinforcing fiber, processing aid and color masterbatch to a high-speed mixer according to the weight ratio, and mix at a speed of 600-900 r / min for 8-15 minutes to obtain a mixture; Step 3: Feed the mixture into a parallel co-rotating twin-screw extruder for melt blending, extrusion, and granulation. The temperature settings for each section of the extruder are determined according to the selected high-temperature resistant polymer: when polyether ether ketone is the main component, then zone 1 is 320-340℃, zone 2 is 350-370℃, zone 3 is 360-380℃, zone 4 is 370-390℃, and the die head temperature is 380-400℃; when polyphenylene sulfide is the main component, then zone 1 is 280-300℃, zone 2 is 300-320℃, zone 3 is 310-330℃, zone 4 is 320-340℃, the die head temperature is 330-350℃, and the screw speed is 150-250 r / min. Step 4: After the extruded strip is cooled by water or air, it is cut into uniform particles by a pelletizer to obtain the high-temperature resistant sheath material.

[0013] Preferably, the manufacturing process of the cable includes the following steps: Step 1: Conductor core preparation: Select tin-plated copper wire or silver-plated copper wire that meets the requirements, strand them into conductive wire cores of a predetermined cross-sectional area using a wire bundling machine, and perform annealing treatment to eliminate internal stress. Step 2: Extrusion of the insulation layer: The prepared insulating composite material particles are fed into an extruder and an insulation layer is formed by extrusion die on the conductor core. The extruder temperature is set to 150-190℃ according to the matrix resin, the screw speed is 10-30r / min, and water cooling is used with the water temperature controlled at 30-50℃. Step 3: Wrapping the shielding layer: Wrap a layer of tinned copper wire braided shielding layer or aluminum-plastic composite tape around the insulation layer, with a shielding coverage of not less than 85%; Step 4: Applying the anti-corrosion layer: The prepared anti-corrosion coating is evenly applied to the outer surface of the shielding layer by high-pressure airless spraying or dip coating. The wet film thickness is controlled at 0.3-0.6 mm. After surface drying at room temperature for 15-30 minutes, it is placed in an oven at 80-120℃ for curing for 30-60 minutes to form the anti-corrosion layer. Step 5: Extrusion of high-temperature resistant sheath layer: The prepared high-temperature resistant sheath material granules are fed into an extruder. Using an extrusion die, a high-temperature resistant sheath layer is formed by extruding it over the anti-corrosion layer. The extruder temperature is set to 280-400℃ according to the high-temperature resistant polymer, and the screw speed is 5-20 r / min. The cooling is done in stages, first by slow cooling with warm water, and then by cooling with cold water. Step Six: Cable Formation and Packaging: For multi-core cables, the single-core cables obtained above are twisted into cables using a cable forming machine, filled with water-blocking rope or wrapped with non-woven fabric, and finally tested for withstand voltage using a spark tester. After passing the test, the cables are rolled up and packaged.

[0014] Preferably, in step four, before coating the anti-corrosion layer, a surface treatment step for the shielding layer is also included: the outer surface of the shielding layer is treated with a low-temperature plasma treatment device, the treatment power is 500-1000W, the treatment time is 2-5 minutes, the treatment gas is argon or oxygen, and the gas flow rate is 20-50 sccm. In step five, after the extrusion of the high-temperature resistant sheath layer, a post-vulcanization treatment step is also included: the cable is placed in a vulcanization oven at 150-200℃ for 2-4 hours for post-vulcanization treatment.

[0015] Preferably, in the process of extruding the high-temperature resistant sheath layer in step five, the extruded sheath layer adopts a segmented gradient cooling method: first, the cable is passed through a warm water cooling tank with a length of 8-12 meters and a water temperature controlled at 60-80℃, and the cooling time is maintained at 30-60 seconds; then, the cable is passed through a normal temperature water cooling tank with a length of 15-20 meters and a water temperature controlled at 10-25℃, and the cooling time is maintained at 60-90 seconds. The traction tension in the segmented gradient cooling process is maintained at 100-300N to ensure that the sheath layer does not deform or have internal stress concentration during the cooling and shaping process.

[0016] Compared with the prior art, the present invention provides a high-temperature resistant and corrosion-resistant cable, which has the following beneficial effects: 1. In this invention, the base resin, high-temperature resistant modifier, and insulating reinforcing filler used in the insulation layer are melt-blended to form a dense composite material system. The nanoscale high-temperature resistant modifier is uniformly dispersed in the base resin, hindering the thermal movement of polymer chains and forming a stable protective barrier at high temperatures, thereby improving the material's heat deformation resistance and insulation stability. At the same time, the insulating reinforcing filler and the resin matrix form a strong interfacial bond, working together to block the migration path of internal electrons and improve the insulation performance and long-term reliability of the cable.

[0017] 2. In this invention, the anti-corrosion layer synergistically constructs a multi-layered protection mechanism through a specific anti-corrosion resin matrix, sheet-like anti-corrosion filler, and nano-anti-corrosion additives. The sheet-like filler is stacked layer by layer in the coating to form a tortuous physical barrier, extending the penetration path of the corrosive medium. The nano-anti-corrosion additives fill the microscopic interface between the filler and the resin, enhancing the density of the coating. In addition, the shielding layer is plasma-treated before coating, which improves the interfacial adhesion between the anti-corrosion coating and the underlying layer, avoiding corrosion channels caused by interlayer peeling, making it difficult for the corrosive medium to penetrate into the conductor, and comprehensively improving the corrosion resistance of the cable.

[0018] 3. In this invention, the high-temperature resistant sheath layer uses a high-performance polymer as the matrix, and forms a rigid network structure with heat-resistant agents and reinforcing fibers, giving the sheath layer excellent thermal stability and mechanical strength, so that it can maintain structural integrity in high-temperature environments and resist external mechanical scratches and impacts; at the same time, the post-vulcanization process after the sheath layer is extruded further promotes the cross-linking of polymer molecules, making the sheath layer structure more stable, releasing internal stress, and tightly bonding with the inner anti-corrosion layer and insulation layer to form a complete heavy-duty protection system, enhancing the overall durability and service life of the cable under complex and harsh working conditions. Detailed Implementation

[0019] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0020] Example 1: A high-temperature resistant and corrosion-resistant cable, comprising, from the inside out, a conductor core, an insulation layer, a shielding layer, a corrosion-resistant layer, and a high-temperature resistant sheath layer; The insulation layer is made of an insulating composite material, which includes the following raw materials in parts by weight: 100 parts of matrix resin, 20 parts of high-temperature resistant modifier, 15 parts of insulating reinforcing filler, 3 parts of compatibilizer, 1 part of antioxidant and 1 part of lubricant. The anti-corrosion layer is formed by coating and curing an anti-corrosion coating, which includes the following raw materials in parts by weight: 80 parts of anti-corrosion resin matrix, 10 parts of flake anti-corrosion filler, 5 parts of nano anti-corrosion additive, 10 parts of curing agent, 30 parts of solvent and 2 parts of additive. The high-temperature resistant sheath layer is made of high-temperature resistant sheath material, which includes the following raw materials in parts by weight: 100 parts of high-temperature resistant polymer, 25 parts of synergistic heat resistant agent, 10 parts of reinforcing fiber, 5 parts of processing aid and 2 parts of color masterbatch.

[0021] The conductor core is a conductive wire core made of multiple tin-plated copper wires or silver-plated copper wires twisted together. The cross-sectional area of ​​the conductive wire core is 1.5mm², the thickness of the insulation layer is 0.8mm, the thickness of the anti-corrosion layer is 0.2mm, and the thickness of the high-temperature resistant sheath layer is 1.5mm. The matrix resin is at least one of ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer and polyolefin elastomer, and the high-temperature modifier is a mixture of at least two of nano magnesium oxide, nano aluminum oxide and nano boron nitride that have been surface treated with silane coupling agent, with a particle size of 30 nm. The insulating reinforcing filler is at least one of calcined kaolin, precipitated barium sulfate, and silica powder, with a particle size of 1 μm; the compatibilizer is maleic anhydride-grafted polyolefin; the antioxidant is a compound of pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] and tris[2,4-di-tert-butylphenyl] phosphite, with a compound weight ratio of 1:1; and the lubricant is at least one of zinc stearate, polyethylene wax, and ethylene bis-stearamide.

[0022] The preparation method of insulating composite materials includes the following steps: The matrix resin was dried in an oven at 80°C for 2 hours until its moisture content was below 0.05%. The dried matrix resin, high-temperature resistant modifier, insulating reinforcing filler, compatibilizer, antioxidant and lubricant are added to a high-speed mixer in proportions by weight and mixed at 500 r / min for 5 minutes to obtain a premix. The premixed material was fed into a twin-screw extruder for melt blending, extrusion, and granulation. The temperatures of each section of the extruder were set as follows: Zone 1 150℃, Zone 2 165℃, Zone 3 170℃, Zone 4 175℃, Die head temperature 180℃, and screw speed 200r / min. After being cooled in a water tank, the extruded strips are cut into uniform particles by a pelletizer to obtain an insulating composite material.

[0023] The anti-corrosion resin matrix is ​​at least one of epoxy resin, modified epoxy resin and phenolic epoxy resin, and the sheet-like anti-corrosion filler is at least one of surface-activated mica powder, glass flakes and aluminum powder, with a sheet diameter of 200 mesh and a thickness of 1 μm. The nano-corrosion inhibitor is at least one of nano-titanium dioxide, nano-zinc oxide, and nano-montmorillonite treated by plasma, with a particle size of 20 nm. The curing agent is at least one of polyamide curing agent, modified amine curing agent, and phenolic amine curing agent. The solvent is a mixed solvent composed of xylene, n-butanol, and cyclohexanone in a weight ratio of 3:1:1. The additives include leveling agent, defoamer, and thixotropic agent. The leveling agent is a polyacrylate leveling agent, the defoamer is an organosilicon defoamer, and the thixotropic agent is fumed silica.

[0024] The preparation method of anti-corrosion coating includes the following steps: Step 1: Add the anticorrosive resin matrix and a portion of the solvent into a dispersion vessel and disperse for 10 minutes at a stirring speed of 300 r / min to obtain a resin solution; Step 2: After drying the flake anticorrosive filler and nano anticorrosive additive at 100℃ for 1 hour, add them and the remaining solvent into a ball mill, use zirconia balls as the grinding medium, the ball-to-material ratio is 5:1, and ball mill at 200 r / min for 2 hours to obtain the filler slurry; Step 3: Mix the obtained resin solution with the obtained filler slurry, add it to the dispersion vessel, and disperse it at a high-speed dispersion rate of 800 r / min for 30 minutes; Step 4: Transfer the evenly dispersed mixture into a grinding device for grinding until the fineness reaches below 20μm; Step 5: Add curing agent and additives to the ground material, and stir at a low speed of 400r / min for 15 minutes to avoid introducing too many air bubbles, so as to obtain a uniform anti-corrosion coating.

[0025] The high-temperature resistant polymer is at least one of polyetheretherketone, polyphenylene sulfide and thermoplastic polyimide, and the synergistic heat resistant agent is a mixture of at least two of nano-silicon carbide, boron phenolic resin and organosilicon modified acrylate resin; The reinforcing fiber is at least one of short-cut glass fiber, basalt fiber and carbon fiber treated with silane coupling agent, with a fiber length of 3 mm. The processing aids include heat stabilizer and lubricant. The heat stabilizer is a compound of hindered phenols and phosphites. The lubricant is at least one of pentaerythritol stearate and lignite wax ester. The color masterbatch is a high-temperature resistant inorganic pigment coloring masterbatch.

[0026] The preparation method of high-temperature resistant sheath material includes the following steps: Step 1: Dry the high-temperature resistant polymer in a vacuum oven at 120°C for 3 hours until its moisture content is below 0.02%; Step 2: Add the dried high-temperature resistant polymer, synergistic heat resistant agent, reinforcing fiber, processing aid and color masterbatch into a high-speed mixer according to the weight ratio, and mix at 600 r / min for 8 minutes to obtain the mixture; Step 3: Feed the mixture into a parallel co-rotating twin-screw extruder for melt blending, extrusion, and granulation. The temperature settings for each section of the extruder are determined according to the selected high-temperature resistant polymer: when polyether ether ketone is the main component, then zone 1 is 320℃, zone 2 is 350℃, zone 3 is 360℃, zone 4 is 370℃, and the die head temperature is 380℃; when polyphenylene sulfide is the main component, then zone 1 is 280℃, zone 2 is 300℃, zone 3 is 310℃, zone 4 is 320℃, and the die head temperature is 330℃, with a screw speed of 150 r / min. Step 4: After the extruded strip is cooled by water or air, it is cut into uniform granules by a pelletizer to obtain high-temperature resistant sheath material.

[0027] The manufacturing process of cables includes the following steps: Step 1: Conductor core preparation: Select tin-plated copper wire or silver-plated copper wire that meets the requirements, strand them into conductive wire cores of a predetermined cross-sectional area using a wire bundling machine, and perform annealing treatment to eliminate internal stress. Step 2: Extrusion of the insulation layer: The prepared insulating composite material particles are fed into an extruder and an extrusion die is used to extrude an insulation layer around the conductor core. The extruder temperature is set to 150℃ according to the matrix resin, the screw speed is 10r / min, and water cooling is used with the water temperature controlled at 30℃. Step 3: Wrapping the shielding layer: Wrap a layer of tinned copper wire braided shielding layer or aluminum-plastic composite tape around the insulation layer, with a shielding coverage of not less than 85%; Step 4: Applying the anti-corrosion layer: The prepared anti-corrosion coating is evenly applied to the outer surface of the shielding layer by high-pressure airless spraying or dip coating. The wet film thickness is controlled at 0.3 mm. After surface drying at room temperature for 15 minutes, it is placed in an 80°C oven to cure for 30 minutes to form the anti-corrosion layer. Step 5: Extrusion of high-temperature resistant sheath layer: The prepared high-temperature resistant sheath material granules are fed into an extruder and a tube-type die is used to extrude a high-temperature resistant sheath layer on the outside of the anti-corrosion layer. The extruder temperature is set to 280℃ according to the high-temperature resistant polymer, the screw speed is 5r / min, and the cooling is staged cooling, first through warm water slow cooling, and then through cold water cooling. Step Six: Cable Formation and Packaging: For multi-core cables, the single-core cables obtained above are twisted into cables using a cable forming machine, filled with water-blocking rope or wrapped with non-woven fabric, and finally tested for withstand voltage using a spark tester. After passing the test, the cables are rolled up and packaged.

[0028] In step four, before applying the anti-corrosion layer, a surface treatment step for the shielding layer is also included: the outer surface of the shielding layer is treated with a low-temperature plasma treatment device with a treatment power of 500W and a treatment time of 2 minutes. The treatment gas is argon or oxygen with a gas flow rate of 20 sccm, in order to increase the adhesion between the shielding layer surface and the anti-corrosion coating. In step five, after extruding the high-temperature resistant sheath layer, a post-vulcanization treatment step is also included: the cable is placed in a vulcanization oven at 150°C for 2 hours for post-vulcanization treatment.

[0029] In step five, during the extrusion of the high-temperature resistant sheath layer, the extruded sheath layer is cooled in a segmented gradient manner: first, the cable is passed through a warm water cooling tank with a length of 8 meters and a water temperature controlled at 60°C for 30 seconds; then, the cable is passed through a normal temperature water cooling tank with a length of 15 meters and a water temperature controlled at 10°C for 60 seconds. The traction tension during the segmented gradient cooling process is maintained at 100N to ensure that the sheath layer does not deform or experience internal stress concentration during the cooling and shaping process.

[0030] Example 2: A high-temperature resistant and corrosion-resistant cable, comprising, from the inside out, a conductor core, an insulation layer, a shielding layer, a corrosion-resistant layer, and a high-temperature resistant sheath layer; The insulation layer is made of an insulating composite material, which includes the following raw materials in parts by weight: 110 parts of matrix resin, 25 parts of high-temperature resistant modifier, 20 parts of insulating reinforcing filler, 5 parts of compatibilizer, 2 parts of antioxidant and 1.5 parts of lubricant; The anti-corrosion layer is formed by coating and curing an anti-corrosion coating, which includes the following raw materials in parts by weight: 90 parts of anti-corrosion resin matrix, 15 parts of flake anti-corrosion filler, 7 parts of nano anti-corrosion additive, 12 parts of curing agent, 40 parts of solvent and 3 parts of additive. The high-temperature resistant sheath layer is made of high-temperature resistant sheath material, which includes the following raw materials in parts by weight: 120 parts of high-temperature resistant polymer, 35 parts of synergistic heat resistant agent, 15 parts of reinforcing fiber, 7 parts of processing aid and 3 parts of color masterbatch.

[0031] The conductor core is a conductive wire core made of multiple tin-plated copper wires or silver-plated copper wires twisted together. The cross-sectional area of ​​the conductive wire core is 45mm², the thickness of the insulation layer is 1.5mm, the thickness of the anti-corrosion layer is 0.4mm, and the thickness of the high-temperature resistant sheath layer is 2.5mm. The matrix resin is at least one of ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer and polyolefin elastomer, and the high-temperature modifier is a mixture of at least two of nano-magnesium oxide, nano-alumina and nano-boron nitride that have been surface-treated with silane coupling agent, with a particle size of 60 nm. The insulating reinforcing filler is at least one of calcined kaolin, precipitated barium sulfate, and silica powder, with a particle size of 5 μm; the compatibilizer is maleic anhydride-grafted polyolefin; the antioxidant is a compound of pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] and tris[2,4-di-tert-butylphenyl] phosphite, with a compound weight ratio of 1:1.5; and the lubricant is at least one of zinc stearate, polyethylene wax, and ethylene bis-stearamide.

[0032] The preparation method of insulating composite materials includes the following steps: The matrix resin was dried in an oven at 90°C for 3 hours until its moisture content was below 0.05%. The dried matrix resin, high-temperature resistant modifier, insulating reinforcing filler, compatibilizer, antioxidant and lubricant are added to a high-speed mixer in proportions by weight and mixed at 600 r / min for 7 minutes to obtain a premix. The premixed material was fed into a twin-screw extruder for melt blending, extrusion, and granulation. The temperatures of each section of the extruder were set as follows: Zone 1 155℃, Zone 2 170℃, Zone 3 175℃, Zone 4 180℃, Die head temperature 185℃, and screw speed 250r / min. After being cooled in a water tank, the extruded strips are cut into uniform particles by a pelletizer to obtain an insulating composite material.

[0033] The anti-corrosion resin matrix is ​​at least one of epoxy resin, modified epoxy resin and phenolic epoxy resin, and the flake anti-corrosion filler is at least one of surface-activated mica powder, glass flakes and aluminum powder, with a flake diameter of 500 mesh and a thickness of 3μm. The nano-corrosion inhibitor is at least one of nano-titanium dioxide, nano-zinc oxide, and nano-montmorillonite treated by plasma, with a particle size of 50 nm. The curing agent is at least one of polyamide curing agent, modified amine curing agent, and phenolic amine curing agent. The solvent is a mixed solvent composed of xylene, n-butanol, and cyclohexanone in a weight ratio of 3:1:1. The additives include leveling agent, defoamer, and thixotropic agent. The leveling agent is a polyacrylate leveling agent, the defoamer is an organosilicon defoamer, and the thixotropic agent is fumed silica.

[0034] The preparation method of anti-corrosion coating includes the following steps: Step 1: Add the anticorrosive resin matrix and a portion of the solvent into a dispersion vessel and disperse for 12 minutes at a stirring speed of 400 r / min to obtain a resin solution; Step 2: After drying the flake anticorrosive filler and nano anticorrosive additive at 110℃ for 1.5 hours, add them and the remaining solvent into a ball mill, use zirconia balls as the grinding medium, the ball-to-material ratio is 7:1, and ball mill at 300 r / min for 3 hours to obtain the filler slurry; Step 3: Mix the obtained resin solution with the obtained filler slurry, add it to the dispersion vessel, and disperse it at a high-speed dispersion rate of 1000 r / min for 45 minutes; Step 4: Transfer the evenly dispersed mixture into a grinding device for grinding until the fineness reaches below 20μm; Step 5: Add curing agent and additives to the ground material, and stir at a low speed of 500r / min for 20 minutes to avoid introducing too many air bubbles, so as to obtain a uniform anti-corrosion coating.

[0035] The high-temperature resistant polymer is at least one of polyetheretherketone, polyphenylene sulfide and thermoplastic polyimide, and the synergistic heat resistant agent is a mixture of at least two of nano-silicon carbide, boron phenolic resin and organosilicon modified acrylate resin; The reinforcing fiber is at least one of short-cut glass fiber, basalt fiber and carbon fiber treated with silane coupling agent, with a fiber length of 5 mm. The processing aids include heat stabilizer and lubricant. The heat stabilizer is a compound of hindered phenols and phosphites. The lubricant is at least one of pentaerythritol stearate and lignite wax ester. The color masterbatch is a high-temperature resistant inorganic pigment coloring masterbatch.

[0036] The preparation method of high-temperature resistant sheath material includes the following steps: Step 1: Dry the high-temperature resistant polymer in a vacuum oven at 135℃ for 5 hours until its moisture content is below 0.02%; Step 2: Add the dried high-temperature resistant polymer, synergistic heat resistant agent, reinforcing fiber, processing aid and color masterbatch into a high-speed mixer according to the weight ratio, and mix at a speed of 750 r / min for 12 minutes to obtain the mixture; Step 3: Feed the mixture into a parallel co-rotating twin-screw extruder for melt blending, extrusion, and granulation. The temperature settings for each section of the extruder are determined according to the selected high-temperature resistant polymer: when polyether ether ketone is the main component, then zone 1 is 330℃, zone 2 is 360℃, zone 3 is 370℃, zone 4 is 380℃, and the die head temperature is 390℃; when polyphenylene sulfide is the main component, then zone 1 is 290℃, zone 2 is 310℃, zone 3 is 320℃, zone 4 is 330℃, and the die head temperature is 340℃, with a screw speed of 200 r / min. Step 4: After the extruded strip is cooled by water or air, it is cut into uniform granules by a pelletizer to obtain high-temperature resistant sheath material.

[0037] The manufacturing process of cables includes the following steps: Step 1: Conductor core preparation: Select tin-plated copper wire or silver-plated copper wire that meets the requirements, strand them into conductive wire cores of a predetermined cross-sectional area using a wire bundling machine, and perform annealing treatment to eliminate internal stress. Step 2: Extrusion of the insulation layer: The prepared insulating composite material particles are fed into an extruder and an extrusion die is used to extrude an insulation layer around the conductor core. The extruder temperature is set to 170℃ according to the matrix resin, the screw speed is 20r / min, and water cooling is used with the water temperature controlled at 40℃. Step 3: Wrapping the shielding layer: Wrap a layer of tinned copper wire braided shielding layer or aluminum-plastic composite tape around the insulation layer, with a shielding coverage of not less than 85%; Step 4: Applying the anti-corrosion layer: The prepared anti-corrosion coating is evenly applied to the outer surface of the shielding layer by high-pressure airless spraying or dip coating. The wet film thickness is controlled at 0.4 mm. After surface drying at room temperature for 25 minutes, it is placed in a 100°C oven to cure for 45 minutes to form the anti-corrosion layer. Step 5: Extrusion of high-temperature resistant sheath layer: The prepared high-temperature resistant sheath material granules are fed into an extruder. Using an extrusion die, a high-temperature resistant sheath layer is formed by extruding it over the anti-corrosion layer. The extruder temperature is set to 350℃ according to the high-temperature resistant polymer, and the screw speed is 10r / min. The cooling is done in stages, first by slow cooling with warm water, and then by cooling with cold water. Step Six: Cable Formation and Packaging: For multi-core cables, the single-core cables obtained above are twisted into cables using a cable forming machine, filled with water-blocking rope or wrapped with non-woven fabric, and finally tested for withstand voltage using a spark tester. After passing the test, the cables are rolled up and packaged.

[0038] In step four, before applying the anti-corrosion layer, a surface treatment step for the shielding layer is also included: the outer surface of the shielding layer is treated with a low-temperature plasma treatment device with a treatment power of 800W and a treatment time of 3 minutes. The treatment gas is argon or oxygen with a gas flow rate of 35 sccm, in order to increase the adhesion between the shielding layer surface and the anti-corrosion coating. In step five, after extruding the high-temperature resistant sheath layer, a post-vulcanization treatment step is also included: the cable is placed in a vulcanization oven at 180°C for 3 hours for post-vulcanization treatment.

[0039] In step five, during the extrusion of the high-temperature resistant sheath layer, the extruded sheath layer is cooled in a segmented gradient manner: first, the cable is passed through a 10-meter-long warm water cooling tank with the water temperature controlled at 70°C for 45 seconds; then, the cable is passed through an 18-meter-long ambient temperature water cooling tank with the water temperature controlled at 20°C for 75 seconds. The traction tension during the segmented gradient cooling process is maintained at 200N to ensure that the sheath layer does not deform or experience internal stress concentration during the cooling and shaping process.

[0040] Example 3: A high-temperature resistant and corrosion-resistant cable, comprising, from the inside out, a conductor core, an insulation layer, a shielding layer, a corrosion-resistant layer, and a high-temperature resistant sheath layer; The insulation layer is made of an insulating composite material, which includes the following raw materials in parts by weight: 120 parts of matrix resin, 30 parts of high-temperature resistant modifier, 25 parts of insulating reinforcing filler, 8 parts of compatibilizer, 3 parts of antioxidant and 2 parts of lubricant. The anti-corrosion layer is formed by coating and curing an anti-corrosion coating, which includes the following raw materials in parts by weight: 100 parts of anti-corrosion resin matrix, 20 parts of flake anti-corrosion filler, 10 parts of nano anti-corrosion additive, 15 parts of curing agent, 50 parts of solvent and 5 parts of additive. The high-temperature resistant sheath layer is made of high-temperature resistant sheath material, which includes the following raw materials in parts by weight: 150 parts of high-temperature resistant polymer, 40 parts of synergistic heat resistant agent, 20 parts of reinforcing fiber, 10 parts of processing aid and 4 parts of color masterbatch.

[0041] The conductor core is a conductive wire core made of multiple tin-plated copper wires or silver-plated copper wires twisted together. The cross-sectional area of ​​the conductive wire core is 95mm², the thickness of the insulation layer is 2.0mm, the thickness of the anti-corrosion layer is 0.5mm, and the thickness of the high-temperature resistant sheath layer is 3.0mm. The matrix resin is at least one of ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer and polyolefin elastomer, and the high-temperature modifier is a mixture of at least two of nano magnesium oxide, nano aluminum oxide and nano boron nitride that have been surface treated with silane coupling agent, with a particle size of 100 nm. The insulating reinforcing filler is at least one of calcined kaolin, precipitated barium sulfate, and silica powder, with a particle size of 10 μm; the compatibilizer is maleic anhydride-grafted polyolefin; the antioxidant is a compound of pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] and tris[2,4-di-tert-butylphenyl] phosphite, with a compound weight ratio of 1:2; and the lubricant is at least one of zinc stearate, polyethylene wax, and ethylene bis-stearamide.

[0042] The preparation method of insulating composite materials includes the following steps: The matrix resin was dried in an oven at 100°C for 4 hours until its moisture content was below 0.05%. The dried matrix resin, high-temperature resistant modifier, insulating reinforcing filler, compatibilizer, antioxidant and lubricant are added to a high-speed mixer in the proportion of weight parts and mixed at 800 r / min for 5-10 minutes to obtain a premix. The premixed material was fed into a twin-screw extruder for melt blending, extrusion, and granulation. The temperatures of each section of the extruder were set as follows: Zone 1 160℃, Zone 2 175℃, Zone 3 180℃, Zone 4 185℃, Die head temperature 190℃, and screw speed 300r / min. After being cooled in a water tank, the extruded strips are cut into uniform particles by a pelletizer to obtain an insulating composite material.

[0043] The anti-corrosion resin matrix is ​​at least one of epoxy resin, modified epoxy resin and phenolic epoxy resin, and the sheet-like anti-corrosion filler is at least one of surface-activated mica powder, glass flakes and aluminum powder, with a sheet diameter of 800 mesh and a thickness of 5 μm. The nano-corrosion inhibitor is at least one of nano-titanium dioxide, nano-zinc oxide, and nano-montmorillonite treated by plasma, with a particle size of 80 nm. The curing agent is at least one of polyamide curing agents, modified amine curing agents, and phenolic amine curing agents. The solvent is a mixed solvent composed of xylene, n-butanol, and cyclohexanone in a weight ratio of 3:1:1. The additives include leveling agents, defoamers, and thixotropic agents. The leveling agent is a polyacrylate leveling agent, the defoamer is an organosilicon defoamer, and the thixotropic agent is fumed silica.

[0044] The preparation method of anti-corrosion coating includes the following steps: Step 1: Add the anticorrosive resin matrix and a portion of the solvent into a dispersion vessel and disperse for 15 minutes at a stirring speed of 500 r / min to obtain a resin solution; Step 2: After drying the sheet-like anti-corrosion filler and nano-anti-corrosion additive at 120℃ for 2 hours, add them and the remaining solvent into a ball mill, use zirconia balls as the grinding medium, the ball-to-material ratio is 10:1, and ball mill at 400 r / min for 4 hours to obtain the filler slurry; Step 3: Mix the obtained resin solution with the obtained filler slurry, add it to the dispersion vessel, and disperse it at a high-speed dispersion rate of 1200 r / min for 60 minutes; Step 4: Transfer the evenly dispersed mixture into a grinding device for grinding until the fineness reaches below 20μm; Step 5: Add curing agent and additives to the ground material, and stir at a low speed of 600r / min for 30 minutes to avoid introducing too many air bubbles, so as to obtain a uniform anti-corrosion coating.

[0045] The high-temperature resistant polymer is at least one of polyetheretherketone, polyphenylene sulfide and thermoplastic polyimide, and the synergistic heat resistant agent is a mixture of at least two of nano-silicon carbide, boron phenolic resin and organosilicon modified acrylate resin; The reinforcing fiber is at least one of short-cut glass fiber, basalt fiber and carbon fiber treated with silane coupling agent, with a fiber length of 6 mm. The processing aids include heat stabilizer and lubricant. The heat stabilizer is a compound of hindered phenols and phosphites. The lubricant is at least one of pentaerythritol stearate and lignite wax ester. The color masterbatch is a high-temperature resistant inorganic pigment coloring masterbatch.

[0046] The preparation method of high-temperature resistant sheath material includes the following steps: Step 1: Dry the high-temperature resistant polymer in a vacuum oven at 150°C for 6 hours until its moisture content is below 0.02%; Step 2: Add the dried high-temperature resistant polymer, synergistic heat resistant agent, reinforcing fiber, processing aid and color masterbatch into a high-speed mixer according to the weight ratio, and mix at a speed of 900 r / min for 8-15 minutes to obtain the mixture; Step 3: Feed the mixture into a parallel co-rotating twin-screw extruder for melt blending, extrusion, and granulation. The temperature settings for each section of the extruder are determined according to the selected high-temperature resistant polymer: when polyetheretherketone is the main component, the temperature is 340℃ for zone 1, 370℃ for zone 2, 380℃ for zone 3, 390℃ for zone 4, and 400℃ for the die head. When polyphenylene sulfide is the main component, the temperature is 300℃ for zone 1, 320℃ for zone 2, 330℃ for zone 3, 340℃ for zone 4, 350℃ for the die head, and the screw speed is 250 r / min. Step 4: After the extruded strip is cooled by water or air, it is cut into uniform granules by a pelletizer to obtain high-temperature resistant sheath material.

[0047] The manufacturing process of cables includes the following steps: Step 1: Conductor core preparation: Select tin-plated copper wire or silver-plated copper wire that meets the requirements, strand them into conductive wire cores of a predetermined cross-sectional area using a wire bundling machine, and perform annealing treatment to eliminate internal stress. Step 2: Extrusion of the insulation layer: The prepared insulating composite material particles are fed into an extruder and an extrusion die is used to extrude an insulation layer around the conductor core. The extruder temperature is set to 190℃ according to the matrix resin, the screw speed is 30r / min, and water cooling is used with the water temperature controlled at 50℃. Step 3: Wrapping the shielding layer: Wrap a layer of tinned copper wire braided shielding layer or aluminum-plastic composite tape around the insulation layer, with a shielding coverage of not less than 85%; Step 4: Applying the anti-corrosion layer: The prepared anti-corrosion coating is evenly applied to the outer surface of the shielding layer by high-pressure airless spraying or dip coating. The wet film thickness is controlled at 0.6 mm. After surface drying at room temperature for 30 minutes, it is placed in a 120°C oven to cure for 60 minutes to form the anti-corrosion layer. Step 5: Extrusion of high-temperature resistant sheath layer: The prepared high-temperature resistant sheath material granules are fed into an extruder. Using an extrusion die, a high-temperature resistant sheath layer is formed by extruding it over the anti-corrosion layer. The extruder temperature is set to 400℃ according to the high-temperature resistant polymer, and the screw speed is 20r / min. The cooling is done in stages, first by slow cooling with warm water, and then by cooling with cold water. Step Six: Cable Formation and Packaging: For multi-core cables, the single-core cables obtained above are twisted into cables using a cable forming machine, filled with water-blocking rope or wrapped with non-woven fabric, and finally tested for withstand voltage using a spark tester. After passing the test, the cables are rolled up and packaged.

[0048] In step four, before applying the anti-corrosion layer, a surface treatment step for the shielding layer is also included: the outer surface of the shielding layer is treated with a low-temperature plasma treatment device with a treatment power of 1000W and a treatment time of 5 minutes. The treatment gas is argon or oxygen with a gas flow rate of 50 sccm, in order to increase the adhesion between the shielding layer surface and the anti-corrosion coating. In step five, after extruding the high-temperature resistant sheath layer, a post-vulcanization treatment step is also included: the cable is placed in a vulcanization oven at 200°C for 4 hours for post-vulcanization treatment.

[0049] In step five, during the extrusion of the high-temperature resistant sheath layer, the extruded sheath layer is cooled in a segmented gradient manner: first, the cable is passed through a 12-meter-long warm water cooling tank with the water temperature controlled at 80°C for 60 seconds; then, the cable is passed through a 20-meter-long ambient temperature water cooling tank with the water temperature controlled at 25°C for 90 seconds. The traction tension during the segmented gradient cooling process is maintained at 300N to ensure that the sheath layer does not deform or experience internal stress concentration during the cooling and shaping process.

[0050] Comparative Example 1: The difference between this comparative example and Example 1 is that no high-temperature resistant modifier was added when preparing the insulating composite material in this comparative example.

[0051] Comparative Example 2 differs from Example 1 in that no nano-anticorrosion additives were added during the preparation of the anticorrosion coating in this comparative example.

[0052] Comparative Example 3 differs from Example 1 in that no synergistic heat-resistant agent was added when preparing the high-temperature resistant sheath material in this comparative example.

[0053] Comparative Example 4 differs from Example 1 in that the shielding layer was not subjected to plasma surface treatment before the anti-corrosion layer was coated.

[0054] The high-temperature resistant and corrosion-resistant cable samples prepared in Examples 1-3 and Comparative Examples 1-4 were subjected to performance tests. The test items and test methods are as follows: Insulation performance testing was conducted in a constant temperature and humidity chamber with a temperature set at 90°C and a relative humidity of 85% for 168 hours. After the sample was removed and cooled to standard conditions at room temperature, the volume resistivity of the insulation layer was measured using a high resistance meter at a DC voltage of 500V. For high-temperature aging performance testing, the cable sample was placed in a forced-ventilation thermal aging test chamber and kept at 200°C for 168 hours. After being removed, it was conditioned in a standard laboratory environment for 24 hours. The changes in tensile strength and elongation at break of the insulation layer and sheath layer before and after aging were measured. For chemical corrosion resistance testing, cable segments with anti-corrosion layers and sheath layers were immersed in 10% hydrochloric acid solution, 10% sodium hydroxide solution and 3.5% sodium chloride solution respectively, and soaked for 168 hours at room temperature (25°C). After removal, the cable segments were rinsed with deionized water and dried. The coating surface was observed for blistering and peeling, and the change in insulation resistance value of the cable before and after immersion was tested. Flame retardant performance testing employs a bundled wire and cable burning test method. A cable sample of a specified length is vertically fixed on a steel ladder, and a propane burner with a specific flow rate is used to burn the bottom of the sample for a specified time from a specified angle and distance. After the test, the char length of the cable and whether it ignites the underlying substrate are evaluated.

[0055] The performance test data of the high-temperature resistant and corrosion-resistant cables prepared in Examples 1-3 and Comparative Examples 1-4 are recorded in the table below: By comparing and analyzing the data in the table, it can be seen that the high-temperature resistant and corrosion-resistant cables prepared using the processes in Examples 1-3 have significantly superior overall performance compared to the cables prepared using the processes in Comparative Examples 1-4. This indicates that the matrix resin, high-temperature resistant modifier, and insulation reinforcing filler used in the insulation layer form a dense composite material system after melt blending. The nanoscale high-temperature resistant modifier is uniformly dispersed in the matrix resin, hindering the thermal movement of the polymer chains and forming a stable protective barrier at high temperatures, thus improving the material's heat deformation resistance and insulation stability. Simultaneously, the insulation reinforcing filler forms a strong interfacial bond with the resin matrix, working together to block the migration path of internal electrons, thereby improving the cable's insulation performance and long-term reliability. The anti-corrosion layer constructs a multi-layered protection mechanism through the synergistic effect of a specific anti-corrosion resin matrix, sheet-like anti-corrosion filler, and nano-anti-corrosion additives. The sheet-like filler is layered in the coating to form a tortuous physical barrier, extending the penetration path of corrosive media. The nano-anti-corrosion additives fill the microscopic interface between the filler and the resin, enhancing the density of the coating. In addition, the shielding layer is plasma-treated before coating, which improves the interfacial adhesion between the anti-corrosion coating and the underlying layer, avoiding corrosion channels caused by interlayer peeling. This makes it difficult for corrosive media to penetrate into the conductor, comprehensively improving the corrosion resistance of the cable. The high-temperature resistant sheath layer uses a high-performance polymer as the matrix, and together with heat-resistant agents and reinforcing fibers, forms a rigid network structure, giving the sheath layer excellent thermal stability and mechanical strength. This allows it to maintain its structural integrity even in high-temperature environments and resist external mechanical scratches and impacts. At the same time, the post-vulcanization process after the sheath layer is extruded further promotes the cross-linking of polymer molecules, making the sheath layer structure more stable, releasing internal stress, and tightly bonding with the inner anti-corrosion layer and insulation layer to form a complete heavy-duty protection system, enhancing the overall durability and service life of the cable under complex and harsh working conditions.

[0056] By comparing and analyzing the relevant data in the table, it can be seen that the high-temperature resistant and corrosion-resistant cable prepared by the molding process of this invention has excellent electrical insulation, corrosion resistance, flame retardancy and long-term thermal stability.

[0057] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0058] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-temperature resistant and corrosion-resistant cable, characterized in that: The cable comprises, from the inside out, a conductor core, an insulation layer, a shielding layer, an anti-corrosion layer, and a high-temperature resistant sheath layer; The insulating layer is made of an insulating composite material, which includes the following raw materials in parts by weight: 100-120 parts of matrix resin, 20-30 parts of high-temperature resistant modifier, 15-25 parts of insulating reinforcing filler, 3-8 parts of compatibilizer, 1-3 parts of antioxidant and 1-2 parts of lubricant. The anti-corrosion layer is formed by coating and curing an anti-corrosion coating, which comprises the following raw materials in parts by weight: 80-100 parts of anti-corrosion resin matrix, 10-20 parts of flake anti-corrosion filler, 5-10 parts of nano anti-corrosion additive, 10-15 parts of curing agent, 30-50 parts of solvent and 2-5 parts of additive. The high-temperature resistant sheath layer is made of a high-temperature resistant sheath material, which includes the following raw materials in parts by weight: 100-150 parts of high-temperature resistant polymer, 25-40 parts of synergistic heat resistant agent, 10-20 parts of reinforcing fiber, 5-10 parts of processing aid, and 2-4 parts of color masterbatch.

2. The high-temperature resistant and corrosion-resistant cable according to claim 1, characterized in that: The conductor core is a conductive wire core made of multiple tin-plated copper wires or silver-plated copper wires twisted together. The cross-sectional area of ​​the conductive wire core is 1.5-95 mm². The thickness of the insulation layer is 0.8-2.0 mm. The thickness of the anti-corrosion layer is 0.2-0.5 mm. The thickness of the high-temperature resistant sheath layer is 1.5-3.0 mm. The matrix resin is at least one of ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer and polyolefin elastomer, and the high-temperature resistant modifier is a mixture of at least two of nano-magnesium oxide, nano-alumina and nano-boron nitride that have been surface treated with silane coupling agent, with a particle size range of 30-100 nm. The insulating reinforcing filler is at least one of calcined kaolin, precipitated barium sulfate, and silica powder, with a particle size range of 1-10 μm. The compatibilizer is maleic anhydride-grafted polyolefin. The antioxidant is a compound of pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate] and tris[2,4-di-tert-butylphenyl] phosphite, with a compound weight ratio of 1:1 to 1:

2. The lubricant is at least one of zinc stearate, polyethylene wax, and ethylene bis-stearamide.

3. The high-temperature resistant and corrosion-resistant cable according to claim 1, characterized in that: The method for preparing the insulating composite material includes the following steps: The matrix resin is dried in an oven at 80-100°C for 2-4 hours until its moisture content is below 0.05%. The dried matrix resin, the high-temperature resistant modifier, the insulating reinforcing filler, the compatibilizer, the antioxidant, and the lubricant are added to a high-speed mixer according to the weight ratio described above, and mixed at a speed of 500-800 r / min for 5-10 minutes to obtain a premix. The premixed material is fed into a twin-screw extruder for melt blending, extrusion, and granulation. The temperatures of each section of the extruder are set as follows: Zone 1 150-160℃, Zone 2 165-175℃, Zone 3 170-180℃, Zone 4 175-185℃, Die head temperature 180-190℃, and screw speed 200-300 r / min. After being cooled in a water tank, the extruded strip is cut into uniform particles by a pelletizer to obtain the insulating composite material.

4. The high-temperature resistant and corrosion-resistant cable according to claim 1, characterized in that: The anti-corrosion resin matrix is ​​at least one of epoxy resin, modified epoxy resin and phenolic epoxy resin, and the sheet-like anti-corrosion filler is at least one of surface-activated mica powder, glass flakes and aluminum powder, with a sheet diameter of 200-800 mesh and a thickness of 1-5 μm. The nano-corrosion inhibitor is at least one of nano-titanium dioxide, nano-zinc oxide, and nano-montmorillonite treated with plasma, with a particle size range of 20-80 nm. The curing agent is at least one of polyamide curing agents, modified amine curing agents, and phenolic amine curing agents. The solvent is a mixed solvent composed of xylene, n-butanol, and cyclohexanone in a weight ratio of 3:1:

1. The additives include leveling agents, defoamers, and thixotropic agents. The leveling agent is a polyacrylate leveling agent, the defoamer is an organosilicon defoamer, and the thixotropic agent is fumed silica.

5. The high-temperature resistant and corrosion-resistant cable according to claim 1, characterized in that: The preparation method of the anti-corrosion coating includes the following steps: Step 1: Add the anticorrosive resin matrix and part of the solvent into a dispersion vessel, and disperse at a stirring speed of 300-500 r / min for 10-15 minutes to obtain a resin solution; Step 2: After drying the sheet-like anti-corrosion filler and nano-anti-corrosion additive at 100-120℃ for 1-2 hours, add them and the remaining solvent into a ball mill, use zirconia balls as the grinding medium, the ball-to-material ratio is 5:1-10:1, and ball mill at a speed of 200-400 r / min for 2-4 hours to obtain the filler slurry. Step 3: Mix the obtained resin solution with the obtained filler slurry, add it to the dispersion vessel, and disperse it at a high-speed dispersion rate of 800-1200 r / min for 30-60 minutes; Step 4: Transfer the evenly dispersed mixture into a grinding device for grinding until the fineness reaches below 20μm; Step 5: Add the curing agent and additives to the ground material, and stir at a low speed of 400-600 r / min for 15-30 minutes to avoid introducing too many air bubbles, so as to obtain a uniform anti-corrosion coating.

6. The high-temperature resistant and corrosion-resistant cable according to claim 1, characterized in that: The high-temperature resistant polymer is at least one of polyetheretherketone, polyphenylene sulfide, and thermoplastic polyimide, and the synergistic heat-resistant agent is a mixture of at least two of nano-silicon carbide, boron phenolic resin, and organosilicon-modified acrylate resin. The reinforcing fiber is at least one of chopped glass fiber, basalt fiber and carbon fiber treated with silane coupling agent, and the fiber length is 3-6 mm. The processing aids include heat stabilizer and lubricant. The heat stabilizer is a compound of hindered phenols and phosphites. The lubricant is at least one of pentaerythritol stearate and lignite wax ester. The color masterbatch is a high-temperature resistant inorganic pigment coloring masterbatch.

7. The high-temperature resistant and corrosion-resistant cable according to claim 1, characterized in that: The preparation method of the high-temperature resistant sheath material includes the following steps: Step 1: Dry the high-temperature resistant polymer in a vacuum oven at 120-150℃ for 3-6 hours until its moisture content is below 0.02%; Step 2: Add the dried high-temperature resistant polymer, the synergistic heat resistant agent, reinforcing fiber, processing aid and color masterbatch to a high-speed mixer according to the weight ratio, and mix at a speed of 600-900 r / min for 8-15 minutes to obtain a mixture; Step 3: Feed the mixture into a parallel co-rotating twin-screw extruder for melt blending, extrusion, and granulation. The temperature settings for each section of the extruder are determined according to the selected high-temperature resistant polymer: when polyether ether ketone is the main component, then zone 1 is 320-340℃, zone 2 is 350-370℃, zone 3 is 360-380℃, zone 4 is 370-390℃, and the die head temperature is 380-400℃; when polyphenylene sulfide is the main component, then zone 1 is 280-300℃, zone 2 is 300-320℃, zone 3 is 310-330℃, zone 4 is 320-340℃, the die head temperature is 330-350℃, and the screw speed is 150-250 r / min. Step 4: After the extruded strip is cooled by water or air, it is cut into uniform particles by a pelletizer to obtain the high-temperature resistant sheath material.

8. The high-temperature resistant and corrosion-resistant cable according to claim 1, characterized in that: The manufacturing process of the cable includes the following steps: Step 1: Conductor core preparation: Select tin-plated copper wire or silver-plated copper wire that meets the requirements, strand them into conductive wire cores of a predetermined cross-sectional area using a wire bundling machine, and perform annealing treatment to eliminate internal stress; Step 2: Extrusion of the insulation layer: The prepared insulating composite material particles are fed into an extruder and an insulation layer is formed by extrusion die on the conductor core. The extruder temperature is set to 150-190℃ according to the matrix resin, the screw speed is 10-30r / min, and water cooling is used with the water temperature controlled at 30-50℃. Step 3: Wrapping the shielding layer: Wrap a layer of tinned copper wire braided shielding layer or aluminum-plastic composite tape around the insulation layer, with a shielding coverage of not less than 85%; Step 4: Applying the anti-corrosion layer: The prepared anti-corrosion coating is evenly applied to the outer surface of the shielding layer by high-pressure airless spraying or dip coating. The wet film thickness is controlled at 0.3-0.6 mm. After surface drying at room temperature for 15-30 minutes, it is placed in an oven at 80-120℃ for curing for 30-60 minutes to form the anti-corrosion layer. Step 5: Extrusion of high-temperature resistant sheath layer: The prepared high-temperature resistant sheath material granules are fed into an extruder. Using an extrusion die, a high-temperature resistant sheath layer is formed by extruding it over the anti-corrosion layer. The extruder temperature is set to 280-400℃ according to the high-temperature resistant polymer, and the screw speed is 5-20 r / min. The cooling is done in stages, first by slow cooling with warm water, and then by cooling with cold water. Step Six: Cable Formation and Packaging: For multi-core cables, the single-core cables obtained above are twisted into cables using a cable forming machine, filled with water-blocking rope or wrapped with non-woven fabric, and finally tested for withstand voltage using a spark tester. After passing the test, the cables are rolled up and packaged.

9. A high-temperature resistant and corrosion-resistant cable according to claim 8, characterized in that: In step four, before coating the anti-corrosion layer, a surface treatment step for the shielding layer is also included: the outer surface of the shielding layer is treated with a low-temperature plasma treatment device, the treatment power is 500-1000W, the treatment time is 2-5 minutes, the treatment gas is argon or oxygen, and the gas flow rate is 20-50 sccm. In step five, after the extrusion of the high-temperature resistant sheath layer, a post-vulcanization treatment step is also included: the cable is placed in a vulcanization oven at 150-200℃ for 2-4 hours for post-vulcanization treatment.

10. A high-temperature resistant and corrosion-resistant cable according to claim 8, characterized in that: In the process of extruding the high-temperature resistant sheath layer in step five, the extruded sheath layer adopts a segmented gradient cooling method: first, the cable is passed through a warm water cooling tank with a length of 8-12 meters and a water temperature controlled at 60-80℃, and the cooling time is maintained at 30-60 seconds; then, the cable is passed through a normal temperature water cooling tank with a length of 15-20 meters and a water temperature controlled at 10-25℃, and the cooling time is maintained at 60-90 seconds. The traction tension in the segmented gradient cooling process is maintained at 100-300N to ensure that the sheath layer does not deform or have internal stress concentration during the cooling and shaping process.

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