Wear-resistant and corrosion-resistant cable and preparation process thereof

Abstract

The invention discloses a wear-resistant and corrosion-resistant cable and a preparation process thereof, and belongs to the technical field of cables. The cable comprises a conductor, an insulating layer, a reinforcing layer, an inner sheath and an outer sheath, wherein the conductor is sequentially coated with the insulating layer, the reinforcing layer, the inner sheath and the outer sheath. The insulating layer contains crosslinked polyethylene, an antioxidant 1010, an antioxidant 168, a graphene oxide and erucyl amide; the enhancement layer is formed by weaving indium-plated copper wires; the inner sheath contains polypropylene, linear low-density polyethylene, polycaprolactone, nano silicon dioxide and the like; the core innovation of the outer sheath is to synergistically add aluminate modified calcium carbonate and bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate; through cooperation of composite components and multi-structure optimization, the wear resistance and corrosion resistance of the cable are remarkably improved, the mechanical property and the anti-oxidation stability are excellent, the process is suitable for industrial production, and the cable can be widely applied to severe environments such as outdoors, chemical engineering and ocean.

Description

Technical Field

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

[0002] Cables, as a key carrier for power transmission and signal transmission, are widely used in various scenarios such as industrial production, construction engineering, transportation, and harsh outdoor environments. In actual use, cables often face problems such as friction, collision, and chemical corrosion, leading to sheath damage and exposed conductors, causing safety hazards such as short circuits and leakage, seriously affecting the cable's service life and safety.

[0003] In existing technologies, inorganic fillers such as talc and calcium carbonate are typically added to the sheath material to improve the wear and corrosion resistance of cables. However, these fillers have poor compatibility with organic substrates and are unevenly dispersed, making it difficult to significantly improve the overall performance of the cable. Some solutions use single modified fillers, such as adding silane-modified montmorillonite or epoxy-modified acrylate emulsions, but these can only improve wear or corrosion resistance in one aspect and cannot achieve synergistic optimization of both. In addition, the reinforcement layer of existing cables mostly uses tin-plated copper wire or silver-plated copper wire, which still suffers from insufficient oxidation resistance in harsh environments, further affecting the overall stability of the cable.

[0004] Therefore, a wear-resistant and corrosion-resistant cable with significantly improved wear and corrosion resistance and its manufacturing process are proposed. Summary of the Invention

[0005] The present invention aims to provide a wear-resistant and corrosion-resistant cable and its manufacturing process, addressing the technical defects of existing cables such as insufficient wear and corrosion resistance, inability to achieve comprehensive performance optimization with a single modified filler, and limited oxidation resistance of the reinforcing layer.

[0006] To achieve the above objectives, the present invention provides the following technical solution: The technical solution provided by this invention is: The wear-resistant and corrosion-resistant cable of the present invention includes an inner sheath and an outer sheath, comprising a conductor, an insulation layer, a reinforcing layer, and an outer sheath. The conductor is made of tin-plated copper wire stranded together, and the conductor is covered by an inner sheath and an outer sheath in sequence.

[0007] The raw material components include the following parts by weight: The insulation layer is made of 100 parts cross-linked polyethylene, 0.8-1.5 parts antioxidant 1010, 0.3-0.6 parts antioxidant 168, 0.1-0.3 parts graphene oxide, and 0.2-0.5 parts erucamide.

[0008] The reinforcing layer is woven from indium-plated copper wire with a diameter of 0.1mm-0.3mm, an indium plating thickness of 0.3μm-0.8μm, a weaving density of not less than 90%, and a weaving pitch of 5mm-15mm.

[0009] The inner sheath is made of a mixture of 30-50 parts polypropylene, 50-70 parts linear low-density polyethylene, 10-15 parts polycaprolactone, 3-8 parts nano-silica with a particle size of 50nm-100nm, 2-5 parts maleic anhydride grafted polyethylene compatibilizer, and 2-4 parts hydroxyapatite.

[0010] The outer sheath is made of a mixture of 70-80 parts methyl vinyl silicone rubber, 20-30 parts fluorosilicone rubber, 10-18 parts calcined kaolin and talc powder, 2-4 parts magnesium hydroxide, 1-3 parts nano-alumina with a particle size of 30nm-80nm, 2-5 parts boron nitride, 3-6 parts polytetrafluoroethylene micro powder, 0.5-1.2 parts silane coupling agent KH-560, 5-9 parts aluminate modified calcium carbonate, and 3-6 parts bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate.

[0011] Among them, the particle size of hydroxyapatite is 80nm-150nm, the particle size of polytetrafluoroethylene micro powder is 1μm-5μm, the particle size of aluminate-modified calcium carbonate is 30nm-60nm, the mass ratio of zirconium phosphate to bisphenol A epoxy resin-modified acrylate emulsion in the composite zirconium phosphate is 1:4-3:7, the particle size after composite is 80nm-120nm, and the ratio of calcined kaolin to talc is 6:4-8:2.

[0012] The manufacturing process of the wear-resistant and corrosion-resistant cable of the present invention includes the following steps: S1 conductor preparation: tin-plated copper wire is stranded according to a set number of strands, and a benzotriazole coating is applied to the outer surface of the stranded conductor with a coating thickness of 0.1μm-0.3μm. The conductor is then dried at 80℃-100℃ for 3min-5min, resulting in a tin plating layer thickness of 0.5μm-2μm. Preparation of S2 insulation layer mixture (parts by weight): Add 100 parts of cross-linked polyethylene, 0.8-1.5 parts of antioxidant 1010, 0.3-0.6 parts of antioxidant 168, 0.1-0.3 parts of graphene oxide, and 0.2-0.5 parts of erucamide to a high-speed mixer. The graphene oxide is first pretreated by ultrasonic dispersion with an ultrasonic power of 300W-500W for 15-20 minutes. Then, it is mixed at 110℃-130℃ for 8-15 minutes with the speed controlled at 600r / min-900r / min. The material is turned over every 3 minutes during the mixing process. S3 insulation layer coating: The mixture obtained from S2 is heated to 120℃-150℃ and coated onto the conductor treated by S1 through a single screw extruder, with a die temperature of 130℃-160℃. S4 reinforcement layer braiding: Indium-plated copper wire is braided onto the outside of the insulation layer using a braiding machine, with the braiding density controlled to be no less than 90% and the braiding pitch 5mm-15mm; Preparation of S5 inner sheath compound (parts by weight): Add 30-50 parts of polypropylene, 50-70 parts of linear low-density polyethylene, 10-15 parts of polycaprolactone, 3-8 parts of nano silica, 2-5 parts of maleic anhydride grafted polyethylene compatibilizer, and 2-4 parts of hydroxyapatite to a high-speed mixer. Preheat polycaprolactone at 80℃-90℃ for 5-8 minutes before adding it. Mix at 100℃-120℃ for 10-20 minutes at a speed of 800r / min-1200r / min. S6 Inner Sheath Covering: The mixture obtained from S5 is heated to 160℃-180℃ and covered with the outside of the reinforcing layer through an extruder; Preparation of S7 aluminate-modified calcium carbonate (parts by weight): Take 100 parts of calcium carbonate, dry it at 110℃-120℃ for 4h-6h to remove moisture, cool it to 60℃-70℃ and add it to a high-speed mixer, add 2-4 parts of aluminate coupling agent dropwise, modify it at 800r / min-1000r / min for 15min-20min, cool it and pass it through a 300-mesh sieve to obtain aluminate-modified calcium carbonate; Preparation of S8 Bisphenol A Epoxy Resin Modified Acrylic Emulsion Composite Zirconia Phosphate (parts by weight): Take 100 parts of bisphenol A epoxy resin modified acrylic emulsion with an epoxy value of 0.2eq / 100g-0.4eq / 100g and a solid content of 40%-50%. Dilute with deionized water to a solid content of 30%-40%. After stirring evenly, slowly add 25-35 parts of zirconium phosphate. Stir and disperse at 300r / min-400r / min for 60min-90min at 40℃-50℃. Then freeze-dry under vacuum at a temperature of -40℃ to -30℃, a vacuum degree of 10Pa-20Pa, and a drying time of 12h-16h. After pulverization, obtain bisphenol A epoxy resin modified acrylic emulsion composite zirconium phosphate. Preparation of S9 outer sheath compound (parts by weight): 70-80 parts of methyl vinyl silicone rubber, 20-30 parts of fluorosilicone rubber, 10-18 parts of a mixture of calcined kaolin and talc, 2-4 parts of magnesium hydroxide, 1-3 parts of nano alumina, 2-5 parts of boron nitride, 3-6 parts of polytetrafluoroethylene micro powder, 0.5-1.2 parts of silane coupling agent KH-560, 5-9 parts of aluminate-modified calcium carbonate prepared by S7, and 3-6 parts of bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate prepared by S8 are added to an internal mixer and mixed at 110℃-130℃ for 15-25 minutes at a speed of 40-60 r / min. S10 outer sheath covering: The mixture obtained from S9 is heated to 170℃-190℃ and covered with the outer sheath through the outer die of a double-layer extruder; S11 Irradiation Crosslinking: The coated cable is placed in an electron beam irradiation device and irradiated with a dose of 50kGy-80kGy for 5min-10min to obtain the finished product.

[0013] The beneficial effects of this technical solution are: (1) This invention improves the cable's wear and corrosion resistance by adding two composite components, aluminate-modified calcium carbonate and bisphenol A epoxy resin-modified acrylate emulsion, to the outer sheath. The synergistic effect of these components significantly enhances the cable's wear resistance and corrosion resistance. Aluminate-modified calcium carbonate has improved surface activity and excellent compatibility with silicone rubber substrates. It can be uniformly dispersed to form a reinforcing network, improving the sheath's hardness and wear resistance. Bisphenol A epoxy resin-modified acrylate emulsion improves the dispersibility of zirconium phosphate. The layered structure of zirconium phosphate can block the penetration of corrosive media, while the epoxy resin groups enhance the bonding force with the substrate, further optimizing corrosion resistance.

[0014] (2) The reinforcing layer uses indium-plated copper wire. Indium has stable chemical properties and better oxidation resistance and corrosion resistance than traditional tin-plated and silver-plated copper wire. It can effectively protect the conductor from external corrosion and extend the service life of the cable.

[0015] (3) Graphene oxide and erucamide are added to the insulation layer. Graphene oxide improves the mechanical strength and heat resistance of the insulation layer, while erucamide acts as a lubricant to improve the processing fluidity and enhance the wear resistance of the insulation layer. Together with the outer sheath, they comprehensively improve the overall wear resistance of the cable.

[0016] (4) Polycaprolactone and hydroxyapatite are added to the inner sheath. Polycaprolactone improves the flexibility and impact resistance of the inner sheath, while hydroxyapatite enhances rigidity and corrosion resistance, forming a buffer protective layer to reduce the damage of external impact to the insulation layer and prevent corrosive media from penetrating into the interior. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the preparation process of a wear-resistant and corrosion-resistant cable and its manufacturing process proposed in this invention. Detailed Implementation

[0018] 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, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention. The specific implementation process is as follows: Example 1: Please see Figure 1The present invention provides a technical solution: a wear-resistant and corrosion-resistant cable and its manufacturing process, comprising the following component proportions: Insulation layer: Cross-linked polyethylene (DH-125Y) 100g, antioxidant 1010 1.2g, antioxidant 168 0.4g, graphene oxide (S28018 (Yuanye Biotechnology)) 0.2g, erucamide 0.3g; Inner sheath: 40g polypropylene (PP 4821 (Nordic Chemicals) halogen-free flame retardant type), 60g linear low-density polyethylene (DFDA-7042), 12g polycaprolactone (PCL-8080 (number average molecular weight 8000)), 5g nano silica, 3g maleic anhydride grafted polyethylene compatibilizer (PE-g-MAH), 3g hydroxyapatite; Outer sheath: 75g of methyl vinyl silicone rubber (MVQ110-1 (vinyl content 0.07-0.12mol%)), 25g of fluorosilicone rubber (FVMQ 9100), 14g of a mixture of calcined kaolin and talc (ratio 7:3), 3g of magnesium hydroxide, 2g of nano alumina, 3g of boron nitride, 4g of polytetrafluoroethylene micro powder (ZF11-1 (conventional type)), 0.8g of silane coupling agent KH-560, 7g of aluminate-modified calcium carbonate, and 4g of bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate (mass ratio of zirconium phosphate to bisphenol A epoxy resin-modified acrylate emulsion 2:5); Reinforcing layer: Indium-plated copper wire, 0.2 mm in diameter, 0.5 μm indium plating thickness, 92% braiding density, and 10 mm braiding pitch; Conductor: Tin-plated copper wire, tin plating thickness 1μm, benzotriazole coating thickness 0.2μm; Preparation process: S1: Conductor preparation: tin-plated copper wire is stranded into 19 strands, and a benzotriazole coating is applied to the outer surface of the stranded conductor. It is then dried at 90°C for 4 min. S2: Preparation of insulating layer mixture: 0.2g of graphene oxide was pretreated by ultrasonic dispersion (ultrasonic power 400W, ultrasonic time 18min). Then, 100g of cross-linked polyethylene, 1.2g of antioxidant 1010, 0.4g of antioxidant 168, 0.2g of pretreated graphene oxide, and 0.3g of erucamide were added to a high-speed mixer and mixed at 120℃ for 12min at a speed of 750r / min. The material was turned over every 3min during the mixing process. S3: Insulation layer coating: The mixture obtained in S2 is heated to 135°C and coated onto the conductor treated in S1 through a single screw extruder at a die temperature of 145°C. S4: Reinforcement layer braiding: Indium-plated copper wire is braided onto the outside of the insulation layer using a braiding machine, with the braiding density controlled at 92% and the braiding pitch at 10mm. S5: Preparation of inner sheath mixture: Preheat 12g of polycaprolactone at 85℃ for 6min, then add it to a high-speed mixer along with 40g of polypropylene, 60g of linear low-density polyethylene, 5g of nano silica, 3g of maleic anhydride grafted polyethylene compatibilizer and 3g of hydroxyapatite, and mix at 110℃ for 15min at a speed of 1000r / min. S6: Inner sheath covering: The mixture obtained in S5 is heated to 170°C and covered with the outside of the reinforcing layer through an extruder; S7: Preparation of aluminate-modified calcium carbonate: Take 100g of calcium carbonate, dry it at 115℃ for 5h to remove moisture, cool it to 65℃ and add it to a high-speed mixer, add 3g of aluminate coupling agent DL-411 dropwise, modify it at 900r / min for 18min, cool it and pass it through a 300-mesh sieve to obtain aluminate-modified calcium carbonate. S8: Preparation of bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate: Take 100g of bisphenol A epoxy resin modified acrylate emulsion, add deionized water to dilute to a solid content of 35%, stir evenly, and slowly add 30g of zirconium phosphate. Stir and disperse at 350r / min at 45℃ for 75min, and then freeze-dry under vacuum at -35℃, vacuum degree 15Pa and drying time 14h. After pulverization, bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate is obtained. S9: Preparation of outer sheath mixture: 75g of methyl vinyl silicone rubber, 25g of fluorosilicone rubber, 14g of a mixture of calcined kaolin and talc, 3g of magnesium hydroxide, 2g of nano alumina, 3g of boron nitride, 4g of polytetrafluoroethylene micro powder, 0.8g of silane coupling agent KH-560, 7g of aluminate-modified calcium carbonate prepared in S7, and 4g of bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate prepared in S8 were added to a mixer and mixed at 120℃ for 20min at a speed of 50r / min. S10: Outer sheath covering: The mixture obtained in S9 is heated to 180°C and covered with the outer sheath through the outer die of a double-layer extruder; S11: Irradiation crosslinking: The coated cable is placed in an electron beam irradiation device and irradiated with a dose of 65kGy for 8 minutes to obtain the finished product; Test Project Test Results Shore hardness 85D Wear 0.08g Tensile strength retention rate after salt spray test 92% Corrosion rate 0.002mm / a Tensile strength 18.5MPa Elongation at break 450% Tensile strength retention rate after heat aging 88% Elongation at break after heat aging 85% The data sheet shows that the cable of Example 1 has excellent overall performance; the Shore hardness reaches 85D, indicating sufficient rigidity of the outer sheath, and the wear amount is only 0.08g, demonstrating good wear resistance. This is due to the good compatibility between aluminate-modified calcium carbonate and the outer sheath substrate, as well as the reinforcing network formed by uniform dispersion; after salt spray testing, the tensile strength retention rate is 92%, and the corrosion rate is as low as 0.002mm / a, reflecting the significant layered barrier effect of bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate, which can effectively block the penetration of corrosive media; the tensile strength is 18.5MPa, and the elongation at break is 450%, indicating that the cable has both good mechanical strength and flexibility, meeting the stress requirements in actual use; after heat aging, the retention rates of the two items are 88% and 85% respectively, indicating that the cable has strong stability in high-temperature environments, excellent oxidation resistance, and can be used for a long time in harsh environments.

[0019] Example 2: Please see Figure 1 The present invention provides a technical solution: a wear-resistant and corrosion-resistant cable and its manufacturing process, comprising the following component proportions: Insulation layer: Cross-linked polyethylene (DH-125Y) 100g, antioxidant 1010 0.8g, antioxidant 168 0.3g, graphene oxide (S28018 (Yuanye Biotechnology)) 0.1g, erucamide 0.2g; Inner sheath: 30g polypropylene (PP 4821 (Nordic Chemicals) halogen-free flame retardant type), 70g linear low-density polyethylene (DFDA-7042), 10g polycaprolactone (PCL-8080 (number average molecular weight 8000)), 3g nano silica, 2g maleic anhydride grafted polyethylene compatibilizer (PE-g-MAH), 2g hydroxyapatite; Outer sheath: 70g methyl vinyl silicone rubber (MVQ110-1 (vinyl content 0.07-0.12mol%)), 30g fluorosilicone rubber (FVMQ 9100), 10g mixture of calcined kaolin and talc (ratio 6:4), 2g magnesium hydroxide, 1g nano alumina, 2g boron nitride, 3g polytetrafluoroethylene micro powder (ZF11-1 (conventional type)), 0.5g silane coupling agent KH-560, 5g aluminate modified calcium carbonate, 3g bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate (zirconium phosphate to bisphenol A epoxy resin modified acrylate emulsion mass ratio 1:4); Reinforcing layer: Indium-plated copper wire, 0.1 mm in diameter, 0.3 μm indium plating thickness, 90% braiding density, and 5 mm braiding pitch; Conductor: Tin-plated copper wire, tin plating thickness 0.5μm, benzotriazole coating thickness 0.1μm; Preparation process: S1: Conductor preparation: Twist tin-plated copper wire into 7 strands, coat the outer surface of the stranded conductor with benzotriazole coating, and dry at 80℃ for 3 min; S2: Preparation of insulating layer mixture: 0.1g of graphene oxide was pretreated by ultrasonic dispersion (ultrasonic power 300W, ultrasonic time 15min). Then, 100g of cross-linked polyethylene, 0.8g of antioxidant 1010, 0.3g of antioxidant 168, 0.1g of pretreated graphene oxide, and 0.2g of erucamide were added to a high-speed mixer and mixed at 110℃ for 8min at a speed of 600r / min. The material was turned over every 3min during the mixing process. S3: Insulation layer coating: The mixture obtained in S2 is heated to 120°C and coated onto the conductor treated in S1 through a single screw extruder at a die temperature of 130°C. S4: Reinforcement layer braiding: Indium-plated copper wire is braided onto the outside of the insulation layer using a braiding machine, with the braiding density controlled at 90% and the braiding pitch at 5mm. S5: Preparation of inner sheath mixture: Preheat 10g of polycaprolactone at 80℃ for 5min, then add it to a high-speed mixer along with 30g of polypropylene, 70g of linear low-density polyethylene, 3g of nano silica, 2g of maleic anhydride grafted polyethylene compatibilizer and 2g of hydroxyapatite, and mix at 100℃ for 10min at a speed of 800r / min. S6: Inner sheath covering: The mixture obtained in S5 is heated to 160°C and covered with the outside of the reinforcing layer through an extruder; S7: Preparation of aluminate-modified calcium carbonate: Take 100g of calcium carbonate, dry it at 110℃ for 4h to remove moisture, cool it to 60℃ and add it to a high-speed mixer, add 2g of aluminate coupling agent DL-411A dropwise, modify it at 800r / min for 15min, cool it and pass it through a 300-mesh sieve to obtain aluminate-modified calcium carbonate. S8: Preparation of bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate: Take 100g of bisphenol A epoxy resin modified acrylate emulsion, add deionized water to dilute to 30% solid content, stir evenly and slowly add 25g of zirconium phosphate, stir and disperse at 300r / min at 40℃ for 60min, then freeze dry under vacuum at -40℃, vacuum degree 10Pa and drying time 12h, and after pulverization, obtain bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate; S9: Preparation of outer sheath mixture: 70g of methyl vinyl silicone rubber, 30g of fluorosilicone rubber, 10g of a mixture of calcined kaolin and talc, 2g of magnesium hydroxide, 1g of nano alumina, 2g of boron nitride, 3g of polytetrafluoroethylene micro powder, 0.5g of silane coupling agent KH-560, 5g of aluminate-modified calcium carbonate prepared in S7, and 3g of bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate prepared in S8 are added to a mixer and mixed at 110℃ for 15min at a speed of 40r / min. S10: Outer sheath covering: The mixture obtained in S9 is heated to 170°C and covered with the outer sheath through the outer die of a double-layer extruder; S11: Irradiation crosslinking: The coated cable is placed in an electron beam irradiation device and irradiated with a dose of 50kGy for 5 minutes to obtain the finished product; Test Project Test Results Shore hardness 82D Wear 0.12g Tensile strength retention rate after salt spray test 88% Corrosion rate 0.003mm / a Tensile strength 16.8MPa Elongation at break 420% Tensile strength retention rate after heat aging 85% Elongation at break after heat aging 82% The data table demonstrates the stability performance of Example 2 using the lower limit of the ratio within the claims; the Shore hardness is 82D and the wear amount is 0.12g, which, although slightly lower than Example 1, is still far superior to traditional cables, indicating that even with only 5g of aluminate-modified calcium carbonate added, the wear resistance of the outer sheath can still be effectively improved; the tensile strength retention rate after salt spray testing is 88%, and the corrosion rate is 0.003mm / a, indicating that 3g of bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate can play a good corrosion resistance role, and the ratio of zirconium phosphate to emulsion of 1:4 can meet the protection requirements of general harsh environments; the tensile strength is 16.8MPa and the elongation at break is 420%, reflecting that the low content of polypropylene and hydroxyapatite in the inner sheath can still balance rigidity and flexibility, and the increased proportion of linear low-density polyethylene makes the sheath more flexible; the retention rates of the two items after heat aging are 85% and 82%, respectively, proving that a small amount of antioxidants and graphene oxides in the insulation layer can achieve good anti-oxidation effects.

[0020] Example 3: Please see Figure 1 The present invention provides a technical solution: a wear-resistant and corrosion-resistant cable and its manufacturing process, comprising the following component proportions: Insulation layer: Cross-linked polyethylene (DH-125Y) 100g, antioxidant 1010 1.5g, antioxidant 168 0.6g, graphene oxide 0.3g, erucamide 0.5g; Inner sheath: 50g polypropylene (PP 4821 (Nordic Chemicals) halogen-free flame retardant type), 50g linear low-density polyethylene (DFDA-7042), 15g polycaprolactone (PCL-8080 (number average molecular weight 8000)), 8g nano silica, 5g maleic anhydride grafted polyethylene compatibilizer (PE-g-MAH), 4g hydroxyapatite; Outer sheath: 80g of methyl vinyl silicone rubber (MVQ110-1 (vinyl content 0.07-0.12mol%)), 20g of fluorosilicone rubber (FVMQ 9100), 18g of a mixture of calcined kaolin and talc (ratio 8:2), 4g of magnesium hydroxide, 3g of nano alumina, 5g of boron nitride, 6g of polytetrafluoroethylene micro powder (ZF11-1 (conventional type)), 1.2g of silane coupling agent KH-560, 9g of aluminate-modified calcium carbonate, and 6g of bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate (mass ratio of zirconium phosphate to bisphenol A epoxy resin-modified acrylate emulsion 3:7); Reinforcing layer: Indium-plated copper wire, 0.3 mm in diameter, 0.8 μm indium plating thickness, 95% braiding density, and 15 mm braiding pitch; Conductor: Tin-plated copper wire, tin plating thickness 2μm, benzotriazole coating thickness 0.3μm; Preparation process: S1: Conductor preparation: Twist tin-plated copper wire into 37 strands, coat the outer surface of the stranded conductor with benzotriazole coating, and dry at 100℃ for 5 min; S2: Preparation of insulating layer mixture: 0.3g of graphene oxide was pretreated by ultrasonic dispersion (ultrasonic power 500W, ultrasonic time 20min). Then, 100g of cross-linked polyethylene, 1.5g of antioxidant 1010, 0.6g of antioxidant 168, 0.3g of pretreated graphene oxide, and 0.5g of erucamide were added to a high-speed mixer and mixed at 130℃ for 15min at a speed of 900r / min. The material was turned over every 3min during the mixing process. S3: Insulation layer coating: The mixture obtained in S2 is heated to 150°C and coated onto the conductor treated in S1 through a single screw extruder at a die temperature of 160°C. S4: Reinforcement layer braiding: Indium-plated copper wire is braided onto the outside of the insulation layer using a braiding machine, with the braiding density controlled at 95% and the braiding pitch at 15mm. S5: Preparation of inner sheath mixture: Preheat 15g of polycaprolactone at 90℃ for 8min, then add it to a high-speed mixer along with 50g of polypropylene, 50g of linear low-density polyethylene, 8g of nano silica, 5g of maleic anhydride grafted polyethylene compatibilizer, and 4g of hydroxyapatite. Mix at 120℃ for 20min at a speed of 1200r / min. S6: Inner sheath covering: The mixture obtained in S5 is heated to 180°C and covered with the outside of the reinforcing layer through an extruder; S7: Preparation of aluminate-modified calcium carbonate: Take 100g of calcium carbonate, dry it at 120℃ for 6h to remove moisture, cool it to 70℃ and add it to a high-speed mixer, add 4g of aluminate coupling agent TMC-102 dropwise, modify it at 1000r / min for 20min, cool it and pass it through a 300-mesh sieve to obtain aluminate-modified calcium carbonate. S8: Preparation of bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate: Take 100g of bisphenol A epoxy resin modified acrylate emulsion, add deionized water to dilute to 40% solid content, stir evenly and slowly add 35g of zirconium phosphate, stir and disperse at 400r / min at 50℃ for 90min, then freeze dry under vacuum at -30℃, vacuum degree 20Pa and drying time 16h, and pulverize to obtain bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate; S9: Preparation of outer sheath mixture: 80g of methyl vinyl silicone rubber, 20g of fluorosilicone rubber, 18g of a mixture of calcined kaolin and talc, 4g of magnesium hydroxide, 3g of nano alumina, 5g of boron nitride, 6g of polytetrafluoroethylene micro powder, 1.2g of silane coupling agent KH-560, 9g of aluminate-modified calcium carbonate prepared in S7, and 6g of bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate prepared in S8 were added to a mixer and mixed at 130℃ for 25min at a speed of 60r / min. S10: Outer sheath covering: The mixture obtained in S9 is heated to 190°C and covered with the outer sheath through the outer die of a double-layer extruder; S11: Irradiation crosslinking: The coated cable is placed in an electron beam irradiation device and irradiated with a dose of 80kGy for 10 minutes to obtain the finished product; Test Project Test Results Shore hardness 88D Wear 0.05g Tensile strength retention rate after salt spray test 95% Corrosion rate 0.001mm / a Tensile strength 20.2MPa Elongation at break 480% Tensile strength retention rate after heat aging 90% Elongation at break after heat aging 88% The data sheet shows the excellent performance of Example 3 using the upper limit ratio; the Shore hardness reaches 88D, and the wear amount is only 0.05g, which is the best wear resistance among all examples. This is because 9g of aluminate-modified calcium carbonate, 6g of polytetrafluoroethylene micro powder, and 5g of boron nitride work synergistically to form a dense reinforcing network, significantly improving the hardness and wear resistance of the outer sheath; after salt spray testing, the tensile strength retention rate is 95%, and the corrosion rate is as low as 0.001mm / a, demonstrating extremely strong corrosion resistance. 6g of bisphenol A epoxy... The high zirconium phosphate content in the resin-modified acrylate emulsion composite zirconium phosphate maximizes its layered barrier effect, effectively preventing the penetration of corrosive media. With a tensile strength of 20.2 MPa and an elongation at break of 480%, the cable exhibits excellent mechanical properties. The inner sheath, containing 50g polypropylene and 4g hydroxyapatite, enhances rigidity, while 15g polycaprolactone ensures flexibility, achieving a perfect balance between strength and toughness. After heat aging, both properties retain 90% and 88% respectively. The synergistic effect of 1.5g antioxidant 1010, 0.6g antioxidant 168, and 0.3g graphene oxide in the insulation layer allows the cable to maintain stable performance even at high temperatures, making it suitable for use in extremely harsh environments.

[0021] Example 4: Please see Figure 1 The present invention provides a technical solution: a wear-resistant and corrosion-resistant cable and its manufacturing process, comprising the following component proportions: Insulation layer: Cross-linked polyethylene (DH-125Y) 100g, antioxidant 1010 1.0g, antioxidant 168 0.5g, graphene oxide (S28018 (Yuanye Biotechnology)) 0.2g, erucamide 0.4g; Inner sheath: 35g polypropylene (PP 4821 (Nordic Chemicals) halogen-free flame retardant type), 65g linear low-density polyethylene (DFDA-7042), 13g polycaprolactone (PCL-8080 (number average molecular weight 8000)), 6g nano silica, 4g maleic anhydride grafted polyethylene compatibilizer (PE-g-MAH), 3g hydroxyapatite; Outer sheath: 72g of methyl vinyl silicone rubber (MVQ110-1 (vinyl content 0.07-0.12mol%)), 28g of fluorosilicone rubber (FVMQ 9100), 16g of a mixture of calcined kaolin and talc (ratio 7:3), 3g of magnesium hydroxide, 2g of nano alumina, 4g of boron nitride, 5g of polytetrafluoroethylene micro powder (ZF11-1 (conventional type)), 1.0g of silane coupling agent KH-560, 8g of aluminate-modified calcium carbonate, and 5g of bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate (mass ratio of zirconium phosphate to bisphenol A epoxy resin-modified acrylate emulsion 2:5); Reinforcing layer: Indium-plated copper wire, 0.2 mm in diameter, 0.6 μm indium plating thickness, 93% braiding density, and 12 mm braiding pitch; Conductor: Tin-plated copper wire, tin plating thickness 1.5μm, benzotriazole coating thickness 0.2μm; Preparation process: S1: Conductor preparation: Twisting tin-plated copper wire into 24 strands, coating the outer surface of the stranded conductor with benzotriazole coating, and drying at 95℃ for 4 min; S2: Preparation of insulating layer mixture: 0.2g of graphene oxide was pretreated by ultrasonic dispersion (ultrasonic power 450W, ultrasonic time 17min). Then, 100g of cross-linked polyethylene, 1.0g of antioxidant 1010, 0.5g of antioxidant 168, 0.2g of pretreated graphene oxide, and 0.4g of erucamide were added to a high-speed mixer and mixed at 125℃ for 13min at a speed of 800r / min. The material was turned over every 3min during the mixing process. S3: Insulation layer coating: The mixture obtained in S2 is heated to 140°C and coated onto the conductor treated in S1 through a single screw extruder at a die temperature of 150°C. S4: Reinforcement layer braiding: Indium-plated copper wire is braided onto the outside of the insulation layer using a braiding machine, with the braiding density controlled at 93% and the braiding pitch at 12mm. S5: Preparation of inner sheath mixture: Preheat 13g of polycaprolactone at 87℃ for 7min, then add it to a high-speed mixer along with 35g of polypropylene, 65g of linear low-density polyethylene, 6g of nano silica, 4g of maleic anhydride grafted polyethylene compatibilizer and 3g of hydroxyapatite, and mix at 115℃ for 18min at a speed of 1100r / min. S6: Inner sheath covering: The mixture obtained in S5 is heated to 175°C and covered with the outside of the reinforcing layer through an extruder; S7: Preparation of aluminate-modified calcium carbonate: Take 100g of calcium carbonate, dry it at 118℃ for 5.5h to remove moisture, cool it to 68℃ and add it to a high-speed mixer, add 3.5g of aluminate coupling agent DL-411 dropwise, modify it at 950r / min for 19min, cool it and pass it through a 300-mesh sieve to obtain aluminate-modified calcium carbonate; S8: Preparation of bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate: Take 100g of bisphenol A epoxy resin modified acrylate emulsion, add deionized water to dilute to a solid content of 38%, stir evenly, and slowly add 32g of zirconium phosphate. Stir and disperse at 380r / min at 48℃ for 80min, and then freeze-dry under vacuum at -32℃, vacuum degree 18Pa and drying time 15h. After pulverization, bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate is obtained. S9: Preparation of outer sheath mixture: 72g of methyl vinyl silicone rubber, 28g of fluorosilicone rubber, 16g of a mixture of calcined kaolin and talc, 3g of magnesium hydroxide, 2g of nano alumina, 4g of boron nitride, 5g of polytetrafluoroethylene micro powder, 1.0g of silane coupling agent KH-560, 8g of aluminate-modified calcium carbonate prepared in S7, and 5g of bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate prepared in S8 were added to a mixer and mixed at 125℃ for 22min at a speed of 55r / min. S10: Outer sheath covering: The mixture obtained in S9 is heated to 185°C and covered with the outer sheath through the outer die of a double-layer extruder; S11: Irradiation crosslinking: The coated cable is placed in an electron beam irradiation device and irradiated with a dose of 70kGy for 9 minutes to obtain the finished product; Test Project Test Results Shore hardness 86D Wear 0.06g Tensile strength retention rate after salt spray test 94% Corrosion rate 0.0015mm / a Tensile strength 19.5MPa Elongation at break 465% Tensile strength retention rate after heat aging 89% Elongation at break after heat aging 86% The data table reflects the balanced performance of the upper limit ratio in Example 4; the Shore hardness is 86D, the wear amount is 0.06g, and the wear resistance is excellent. The synergistic effect of 8g aluminate-modified calcium carbonate, 2g nano-alumina, and 4g boron nitride improves the hardness of the outer sheath without sacrificing flexibility; the tensile strength retention rate after salt spray test is 94%, the corrosion rate is 0.0015mm / a, and the corrosion resistance is close to that of Example 3. The 2:5 ratio of zirconium phosphate to emulsion in the 5g bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate achieves a balance between dispersibility and barrier properties, effectively resisting the erosion of corrosive media; the tensile strength is 19.5MPa, and the elongation at break is 465%, demonstrating good comprehensive mechanical properties. The ratio of 35g polypropylene, 13g polycaprolactone, and 3g hydroxyapatite in the inner sheath is reasonable, balancing rigidity and flexibility; the retention rates of the two components after heat aging are 89% and 86%, respectively. The insulation layer contains 1.0g antioxidant 1010 and 0.5g antioxidant 168. The synergistic effect of 0.4g erucamide gives the cable both good oxidation resistance and processing fluidity, making it suitable for long-term use in complex outdoor environments.

[0022] Comparative Example 1: Please see Figure 1 The present invention provides a comparative scheme: Insulation layer: 100g cross-linked polyethylene, 1.2g antioxidant 1010, 0.4g antioxidant 168 (no graphene oxide or erucamide). Inner sheath: 40g polypropylene, 60g linear low-density polyethylene, 5g nano silica, 3g maleic anhydride grafted polyethylene compatibilizer (without polycaprolactone or hydroxyapatite). Outer sheath: 75g methyl vinyl silicone rubber, 25g fluorosilicone rubber, 14g mixture of calcined kaolin and talc (ratio 7:3), 3g magnesium hydroxide, 2g nano alumina, 3g boron nitride, 4g polytetrafluoroethylene micro powder, 0.8g silane coupling agent KH-560 (aluminate-free modified calcium carbonate, bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate); Reinforcing layer: Tin-plated copper wire, 0.2 mm in diameter, 1 μm tin plating thickness, 92% braiding density, 10 mm braiding pitch (no indium plating). Conductor: Tin-plated copper wire, tin plating thickness 1μm (without benzotriazole coating); Preparation process: No S7 or S8 steps, and no benzotriazole coating or drying steps in S1; The rest is the same as in Example 1; Test Project Test Results Shore hardness 75D Wear 0.35g Tensile strength retention rate after salt spray test 65% Corrosion rate 0.015mm / a Tensile strength 14.2MPa Elongation at break 380% Tensile strength retention rate after heat aging 70% Elongation at break after heat aging 68% This data sheet reveals the performance shortcomings of conventional cables in the prior art; the Shore hardness is only 75D, and the wear amount is as high as 0.35g, indicating poor wear resistance. This is because the outer sheath does not contain wear-resistant modifying components such as aluminate-modified calcium carbonate, and the traditional inorganic filler has poor compatibility with the substrate, resulting in uneven dispersion and an inability to form an effective reinforcing network. After salt spray testing, the tensile strength retention rate is only 65%, and the corrosion rate is 0.015mm / a, indicating corrosion resistance far lower than that of the embodiments of this invention. This is due to the lack of layered barrier properties of bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate. The cable's performance is compromised by several factors: corrosive media easily penetrate the cable's interior, leading to a significant decrease in sheath performance; its tensile strength is 14.2 MPa and elongation at break is 380%, indicating mediocre mechanical properties; the inner sheath lacks polycaprolactone and hydroxyapatite, failing to provide effective buffer protection and impacting overall load-bearing capacity; after thermal aging, the retention rates of the two components are only 70% and 68%, respectively; the reinforcement layer uses traditional tin-plated copper wire, which has insufficient oxidation resistance; and the insulation layer lacks graphene oxide and erucamide, making it prone to aging at high temperatures, resulting in a short overall service life and failing to meet the requirements for use in harsh environments.

[0023] Comparative Example 2: Please see Figure 1 The present invention provides a comparative scheme: Outer sheath: Bisphenol A-free epoxy resin modified acrylate emulsion composite zirconium phosphate; Preparation process: No S8 step; The rest is the same as in Example 1; Test Project Test Results Shore hardness 84D Wear 0.10g Tensile strength retention rate after salt spray test 75% Corrosion rate 0.008mm / a Tensile strength 17.2MPa Elongation at break 430% Tensile strength retention rate after heat aging 82% Elongation at break after heat aging 80% The data table shows the performance limitations of adding only a single composite component; the Shore hardness is 84D, the wear amount is 0.10g, and the wear resistance is good, close to that of Example 1, indicating that aluminate-modified calcium carbonate can effectively improve the hardness and wear resistance of the outer sheath. Its good compatibility with the substrate ensures uniform dispersion and forms an effective reinforcing network; however, the corrosion resistance is poor, with only 75% of the tensile strength retention rate after salt spray testing and a corrosion rate of 0.008mm / a, far lower than 92% and 0.002mm / a of Example 1. The core reason is the lack of bisphenol A epoxy resin modified propylene. The ester emulsion composite zirconium phosphate lacks a layered barrier structure, making it susceptible to penetration by corrosive media, which leads to a rapid decline in the performance of the sheath under salt spray conditions. The tensile strength is 17.2 MPa, the elongation at break is 430%, and the mechanical properties and thermal aging properties (retention rates of 82% and 80%, respectively) are not significantly different from those of Example 1, because the composition and structure of the insulation layer, inner sheath, and reinforcing layer remain unchanged, and they can still perform their respective functions. This proves that adding only a single composite component cannot simultaneously achieve synergistic optimization of wear resistance and corrosion resistance; two composite components must work together to achieve the comprehensive performance effect of this invention.

[0024] Comparative Example 3: Please see Figure 1 The present invention provides a comparative scheme: Outer sheath: Aluminate-free modified calcium carbonate; Preparation process: No S7 step; The rest is the same as in Example 1; Test Project Test Results Shore hardness 78D Wear 0.22g Tensile strength retention rate after salt spray test 90% Corrosion rate 0.003mm / a Tensile strength 16.5MPa Elongation at break 410% Tensile strength retention rate after heat aging 83% Elongation at break after heat aging 81% This data table highlights the performance limitations of adding only a single composite component. After salt spray testing, the tensile strength retention rate was 90%, and the corrosion rate was 0.003 mm / a, indicating good corrosion resistance, similar to Example 1. This demonstrates that the bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate can effectively improve corrosion resistance; its layered structure can block the penetration of corrosive media, and the epoxy resin groups enhance the bonding force with the substrate. However, the wear resistance is poor, with a Shore hardness of only 78D and an wear amount of 0.22g, far exceeding the 85D and 0.08g of Example 1. This is because no aluminate-modified calcium carbonate was added, resulting in a lack of effective wear-enhancing properties in the outer sheath. The strong network shows that the wear resistance cannot be significantly improved by relying solely on polytetrafluoroethylene micropowder and boron nitride; the tensile strength is 16.5 MPa and the elongation at break is 410%, which are slightly lower than those of Example 1. Due to the insufficient hardness of the outer sheath, the overall force transmission effect is affected; the thermal aging performance is good, with retention rates of 83% and 81% respectively. Because the composition of the insulation layer, inner sheath, and reinforcing layer remains unchanged, they can still play a role in anti-oxidation and structural stability. This further proves that the synergistic effect of the two composite components is the key to achieving a significant improvement in wear resistance and corrosion resistance at the same time. A single component cannot achieve the technical effect of this invention.

[0025] Comparative Example 4: Please see Figure 1 The present invention provides a comparative scheme: Outer sheath: 7g of ordinary calcium carbonate, 50nm particle size (replacing aluminate-modified calcium carbonate); Preparation process: No S7 step, 7g of ordinary calcium carbonate is directly added to the outer sheath mixture; The rest is the same as in Example 1; Test Project Test Results Shore hardness 76D Wear 0.28g Tensile strength retention rate after salt spray test 80% Corrosion rate 0.006mm / a Tensile strength 15.8MPa Elongation at break 400% Tensile strength retention rate after heat aging 81% Elongation at break after heat aging 79% The data shows a performance decline after the unmodified component was substituted; the Shore hardness was 76D, the wear amount was 0.28g, and the wear resistance was far lower than that of Example 1. This is because ordinary calcium carbonate has low surface activity, poor compatibility with the outer sheath silicone rubber substrate, uneven dispersion, and cannot form an effective reinforcing network. Therefore, it cannot improve the sheath hardness and wear resistance like aluminate-modified calcium carbonate. After salt spray testing, the tensile strength retention rate was 80%, the corrosion rate was 0.006mm / a, and the corrosion resistance also decreased. The poor dispersion of ordinary calcium carbonate affected the effectiveness of other anti-corrosion components, leading to a decrease in corrosion resistance. The material is more easily penetrated; the tensile strength is 15.8 MPa, the elongation at break is 400%, the mechanical properties are poor, the outer sheath structure is loose, it is easy to deform under stress, and it cannot effectively protect the internal insulation layer and conductor; the retention rates of the two heat aging performance are 81% and 79%, which are better than Comparative Example 1, but still lower than Example 1, because the composition of the insulation layer and the reinforcing layer remains unchanged, but the performance of the outer sheath is reduced, which indirectly affects the overall stability; this shows that aluminate modification treatment is the key to improving the compatibility of calcium carbonate with the substrate and the wear resistance of the cable, and ordinary unmodified calcium carbonate cannot achieve the technical effect of this invention.

[0026] Comparative Example 5: Please see Figure 1 The present invention provides a comparative scheme: Outer sheath: 4g of ordinary acrylate emulsion composite zirconium phosphate (the mass ratio of zirconium phosphate to ordinary acrylate emulsion is 2:5, replacing bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate). Preparation process: In step S8, 100g of ordinary acrylate emulsion is used to replace the bisphenol A epoxy resin modified acrylate emulsion; The rest is the same as in Example 1; Test Project Test Results Shore hardness 83D Wear 0.11g Tensile strength retention rate after salt spray test 78% Corrosion rate 0.007mm / a Tensile strength 16.2MPa Elongation at break 420% Tensile strength retention rate after heat aging 82% Elongation at break after heat aging 80% This data sheet reflects the performance defects of the unmodified emulsion composite component; the Shore hardness is 83D, and the wear amount is 0.11g, indicating good wear resistance, similar to Example 1, because the aluminate-modified calcium carbonate functions properly, improving the hardness and wear resistance of the outer sheath; however, the corrosion resistance is significantly reduced, with only 78% of the tensile strength retention after salt spray testing and a corrosion rate of 0.007mm / a, far lower than 92% and 0.002mm / a in Example 1. This is because the ordinary acrylic emulsion lacks epoxy resin groups, resulting in poor adhesion to the outer sheath substrate and an inability to effectively improve the dispersibility of zirconium phosphate, making the layered barrier effect of zirconium phosphate difficult to achieve. The corrosive medium easily penetrates into the sheath; the tensile strength is 16.2 MPa, and the elongation at break is 420%, which is slightly lower than that of Example 1. Due to the decreased corrosion resistance of the sheath, the overall structural stability is affected; the retention rates of the two thermal aging properties are 82% and 80%, which are close to those of Comparative Example 2, because the composition of the insulation layer, inner sheath, and reinforcing layer remains unchanged. However, the insufficient corrosion resistance of the outer sheath will still affect the long-term service life of the cable; this indicates that bisphenol A epoxy resin modification is the key to improving the bonding force between the acrylate emulsion and the substrate and the dispersibility of zirconium phosphate. Ordinary acrylate emulsions cannot achieve the corrosion resistance effect of this invention.

[0027] This technical solution introduces two composite components—aluminate-modified calcium carbonate and bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate—into the outer sheath. Combined with structural and compositional optimization of the inner sheath of the reinforcing insulation layer, this solution completely resolves the technical pain points of existing cables, such as difficulty in synergistically improving wear and corrosion resistance and poor adaptability to extreme environments. Performance data shows that the cables in Examples 1 to 4 exhibit wear amounts of only 0.05g to 0.12g and Shore hardness of 82D to 88D, far superior to the 0.35g wear amount and 75D hardness of the conventional cable in Comparative Example 1. They are also significantly superior to Comparative Examples 2 and 3, which only added a single composite component. Comparative Example 2 exhibited a wear amount of 0.10g but a tensile strength retention rate of only 75% after salt spray testing, while Comparative Example 3 retained 90% of its tensile strength after salt spray testing but had a wear amount as high as 0.22g. This fully demonstrates that the synergistic effect of the two composite components is key to achieving simultaneous optimization of wear and corrosion resistance. In terms of corrosion resistance, the corrosion rate of the examples was as low as 0.001 mm / a to 0.003 mm / a, and the tensile strength retention rate after salt spray testing was 88% to 95%. In contrast, the corrosion rate of Comparative Example 1 was 0.015 mm / a and the retention rate was 65%. The corrosion rate of Comparative Example 4, which replaced the aluminate-modified calcium carbonate with ordinary calcium carbonate, was 0.006 mm / a and the retention rate was 80%. The corrosion rate of Comparative Example 5, which replaced the bisphenol A epoxy resin-modified acrylate emulsion with ordinary acrylate emulsion, was 0.007 mm / a and the retention rate was 78%. The difference was significant. This is because the aluminate modification treatment improved the compatibility between calcium carbonate and silicone rubber substrate, forming a dense reinforcing network. The bisphenol A epoxy resin-modified acrylate emulsion optimized the dispersibility of zirconium phosphate, and its layered structure effectively blocked the penetration of corrosive media. Meanwhile, this technology achieves a tensile strength of 16.8 MPa to 20.2 MPa and an elongation at break of 420% to 480% through multi-structure synergistic optimization by using indium-plated copper wire in the reinforcing layer, adding graphene oxide and erucamide to the insulating layer, and introducing polycaprolactone and hydroxyapatite into the inner sheath. After heat aging, the retention rates of tensile strength and elongation at break both exceed 82%, while the tensile strength of Comparative Example 1 is only 14.2 MPa and the retention rate after heat aging is 70%, demonstrating the comprehensive improvement of mechanical properties and antioxidant stability of this technology. In summary, this technical solution breaks through the limitations of existing technologies that rely on single modification or conventional filler addition. Through the combination of synergistic composite components, multi-structure optimization, and precise process control, it achieves simultaneous improvement in the mechanical properties of cable wear resistance, corrosion resistance, and oxidation resistance, expanding the applicable scenarios from general outdoor environments to extreme harsh environments such as marine chemical plants.

[0028] To further illustrate the beneficial technical effects of the wear-resistant and corrosion-resistant cables and their manufacturing processes according to the embodiments of the present invention, relevant performance tests were conducted on the wear-resistant and corrosion-resistant cables and their manufacturing processes according to Examples 1-4 and Comparative Examples 1-5; the test methods are as follows: 1. Shore Hardness: The surface hardness of the outer sheath is directly tested using a Shore hardness tester; 2. Wear amount: Weigh the sample before and after 30 minutes of wear under a load of 10N and a rotation speed of 500r / min; 3. Tensile strength retention rate after salt spray test: The ratio of the tensile strength calculated after 1000 hours of testing at 35℃ and 5% salt spray concentration to the initial value; 4. Corrosion rate: Calculate the corrosion thickness per unit time by measuring the change in sheath thickness after salt spray testing; 5. Tensile strength: The maximum tensile load of the test sheath specimen is converted into a strength value; 6. Elongation at break: The ratio of the elongation at break of the test sheath specimen to its initial length; 7. Retention rate after heat aging: The ratio of tensile strength and elongation at break measured after aging at 120℃ for 168h to the initial value is calculated.

[0029] The above descriptions are merely embodiments of the present invention, and common knowledge regarding specific technical solutions or characteristics is not elaborated upon here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A wear-resistant and corrosion-resistant cable, characterized in that, It includes a conductor, an insulating layer, a reinforcing layer, an inner sheath, and an outer sheath. The conductor is made of tinned copper wire stranded together, and is covered with an insulation layer, a reinforcement layer, an inner sheath, and an outer sheath in sequence. The raw material components include the following parts by weight: The insulation layer is made of a mixture of 100 parts cross-linked polyethylene, 0.8-1.5 parts antioxidant 1010, 0.3-0.6 parts antioxidant 168, 0.1-0.3 parts graphene oxide, and 0.2-0.5 parts erucamide. The reinforcing layer is woven from indium-plated copper wire; The inner sheath is made of a mixture of 30-50 parts polypropylene, 50-70 parts linear low-density polyethylene, 10-15 parts polycaprolactone, 3-8 parts nano-silica with a particle size of 50nm-100nm, 2-5 parts maleic anhydride grafted polyethylene compatibilizer, and 2-4 parts hydroxyapatite. The outer sheath is made of 70-80 parts of methyl vinyl silicone rubber, 20-30 parts of fluorosilicone rubber, 10-18 parts of a mixture of calcined kaolin and talc, 2-4 parts of magnesium hydroxide, 1-3 parts of nano-alumina with a particle size of 30nm-80nm, 2-5 parts of boron nitride, 3-6 parts of polytetrafluoroethylene micro powder, 0.5-1.2 parts of silane coupling agent KH-560, 5-9 parts of aluminate-modified calcium carbonate, and 3-6 parts of bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate.

2. The wear-resistant and corrosion-resistant cable according to claim 1, characterized in that, The conductor has a tin plating layer thickness of 0.5μm-2μm, and the outer surface of the conductor is coated with a benzotriazole coating with a thickness of 0.1μm-0.3μm.

3. The wear-resistant and corrosion-resistant cable according to claim 1, characterized in that, The diameter of the indium-plated copper wire in the reinforcing layer is 0.1mm-0.3mm, the thickness of the indium plating layer is 0.3μm-0.8μm, the braiding density is not less than 90%, and the braiding pitch is 5mm-15mm.

4. The wear-resistant and corrosion-resistant cable according to claim 1, characterized in that, The particle size of hydroxyapatite is 80nm-150nm, the particle size of polytetrafluoroethylene micro powder is 1μm-5μm, the particle size of aluminate-modified calcium carbonate is 30nm-60nm, and the mass ratio of zirconium phosphate to bisphenol A epoxy resin-modified acrylate emulsion in the composite zirconium phosphate is 1:4-3:7, resulting in a particle size of 80nm-120nm after composite formation.

5. The wear-resistant and corrosion-resistant cable according to claim 1, characterized in that, The ratio of calcined kaolin to talc is 6:4-8:

2.

6. A manufacturing process for the wear-resistant and corrosion-resistant cable according to any one of claims 1-5, characterized in that, Includes the following steps: S1: Conductor preparation: Twist tin-plated copper wires according to the set number of strands, coat the outer surface of the stranded conductor with benzotriazole coating, and dry at 80℃-100℃ for 3min-5min; S2: Preparation of insulation layer mixture (parts by weight): Add 100 parts of cross-linked polyethylene, 0.8-1.5 parts of antioxidant 1010, 0.3-0.6 parts of antioxidant 168, 0.1-0.3 parts of graphene oxide, and 0.2-0.5 parts of erucamide to a high-speed mixer and mix at 110℃-130℃ for 8-15 minutes, with the speed controlled at 600r / min-900r / min. During the mixing process, the material is turned over once every 3 minutes. S3: Insulation layer coating: The mixture obtained in S2 is heated to 120℃-150℃ and coated onto the conductor treated in S1 through a single screw extruder, with a die temperature of 130℃-160℃. S4: Reinforcement layer braiding: Indium-plated copper wire is braided onto the outside of the insulation layer using a braiding machine, controlling the braiding density and braiding pitch; S5: Preparation of inner sheath mixture (parts by weight): Add 30-50 parts of polypropylene, 50-70 parts of linear low-density polyethylene, 10-15 parts of polycaprolactone, 3-8 parts of nano silica, 2-5 parts of maleic anhydride grafted polyethylene compatibilizer, and 2-4 parts of hydroxyapatite to a high-speed mixer and mix at 100℃-120℃ for 10-20 minutes at a speed of 800r / min-1200r / min. S6: Inner sheath covering: The mixture obtained in S5 is heated to 160℃-180℃ and covered with the outside of the reinforcing layer through an extruder; S7: Preparation of aluminate-modified calcium carbonate (parts by weight): Take 100 parts of calcium carbonate, dry it at 110℃-120℃ for 4h-6h to remove moisture, cool it to 60℃-70℃ and add it to a high-speed mixer, add 2-4 parts of aluminate coupling agent dropwise, modify it at 800r / min-1000r / min for 15min-20min, cool it and pass it through a 300-mesh sieve to obtain aluminate-modified calcium carbonate; S8: Preparation of bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate (parts by weight): Take 100 parts of bisphenol A epoxy resin modified acrylate emulsion, add deionized water to dilute to a solid content of 30%-40%, stir evenly, and slowly add 25-35 parts of zirconium phosphate. Stir and disperse at 300r / min-400r / min at 40℃-50℃ for 60min-90min. Then freeze-dry under vacuum and pulverize to obtain bisphenol A epoxy resin modified acrylate emulsion composite zirconium phosphate. S9: Preparation of outer sheath mixture (parts by weight): 70-80 parts of methyl vinyl silicone rubber, 20-30 parts of fluorosilicone rubber, 10-18 parts of a mixture of calcined kaolin and talc, 2-4 parts of magnesium hydroxide, 1-3 parts of nano alumina, 2-5 parts of boron nitride, 3-6 parts of polytetrafluoroethylene micro powder, 0.5-1.2 parts of silane coupling agent KH-560, 5-9 parts of aluminate-modified calcium carbonate prepared in S7, and 3-6 parts of bisphenol A epoxy resin-modified acrylate emulsion composite zirconium phosphate prepared in S8 are added to a mixer and mixed at 110℃-130℃ for 15-25 minutes at a speed of 40-60 r / min. S10: Outer sheath covering: The mixture obtained in S9 is heated to 170℃-190℃ and covered with the outer sheath through the outer die of a double-layer extruder; S11： Irradiation crosslinking: The coated cable is placed in an electron beam irradiation device and irradiated with a dose of 50kGy-80kGy for 5min-10min to obtain the finished product.

7. The preparation process according to claim 6, characterized in that, The graphene oxide in S2 needs to be pretreated by ultrasonic dispersion, with an ultrasonic power of 300W-500W and an ultrasonic time of 15min-20min.

8. The preparation process according to claim 6, characterized in that, Polycaprolactone in S5 needs to be preheated at 80℃-90℃ for 5-8 minutes before being added to the high-speed mixer.

9. The preparation process according to claim 6, characterized in that, The vacuum freeze-drying temperature in S8 is -40℃ to -30℃, the vacuum degree is 10Pa to 20Pa, and the drying time is 12h to 16h.

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