Universal sensing type intelligent temperature control cable and preparation method thereof

Abstract

The invention discloses a global sensing type intelligent temperature control cable and a preparation method thereof, and the cable comprises a conductor, an inner insulating layer, an intelligent sensing response layer, an outer insulating layer, a fireproof layer, an electromagnetic shielding layer and a sheath layer, and the intelligent sensing response layer comprises a polyimide composite belt, a sensing micropipe and a liquid cooling micropipe. Perfluoropolyether cooling liquid and gallium-indium-tin liquid metal micro-droplets are filled in the sensing micro-tubes, high-thermal-conductivity nano-fluid is filled in the liquid-cooling micro-tubes, and the sensing micro-tubes and the liquid-cooling micro-tubes form a sensing channel and a temperature control channel through parallel design respectively; inlets and outlets of the sensing channel and the temperature control channel are arranged at the end part of the cable and are integrated with a double-cavity micro piezoelectric pump and a double-cavity micro radiator to form a sensing array and a temperature control array, and an embedded edge controller electrically connected with a sensing micro tube is integrated in the double-cavity micro piezoelectric pump. According to the invention, transmission, heat dissipation and sensing are integrated, and accurate positioning of various faults such as extrusion, cutting, overheating and the like is realized.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a global sensing intelligent temperature control cable and its preparation method. Background Technology

[0002] In Industry 4.0, smart manufacturing, and high-power applications (such as supercharging, data centers, and high-end equipment), cables are not only the carriers of energy and signals, but also key bottlenecks affecting system power density, energy efficiency, and reliability. Existing cable technologies, even some so-called "smart" or "fire-resistant" cables, still suffer from the following fundamental defects and technological gaps: 1) The level of intelligence is superficial, lacking predictive diagnosis and visualization interaction capabilities. For example, most existing smart cables use external or discrete sensors (such as point thermocouples and distributed optical fibers), which have problems such as monitoring blind spots, complex installation, and low reliability; at the same time, they completely lack intrinsic sensing capabilities and cannot monitor their own temperature, strain, vibration, and internal pressure in real time and across the entire domain like biological nerves.

[0003] 2) Safety and thermal management mechanisms are passive and outdated, unable to support the development of high power density. For example, traditional fire-resistant cables rely on the "passive defense" mode of material sacrifice, only seeking to "survive" in extreme fire conditions, unable to actively intervene in the fire (such as active cooling), and have no ability to recover their functions after damage; at the same time, facing the ever-increasing transmission power (such as electric vehicle supercharging, server clusters), traditional air cooling or natural heat dissipation methods have reached their limits.

[0004] Therefore, it is necessary to develop a native smart cable that integrates intrinsic sensing and active temperature control. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies by proposing a fully sensing intelligent temperature control cable and its preparation method, which integrates transmission, heat dissipation, and sensing, and achieves precise location of various faults such as extrusion, cutting, and overheating.

[0006] The technical solution to achieve the objective of this invention is: A global sensing intelligent temperature control cable includes, from the inside out, a conductor, an inner insulation layer, an intelligent sensing response layer, an outer insulation layer, a fire-resistant layer, an electromagnetic shielding layer, and a sheath layer. The intelligent sensing response layer includes a polyimide composite tape and sensing microtubes and liquid-cooled microtubes embedded in the polyimide composite tape and evenly spaced along the circumference. The sensing microtubes are filled with perfluoropolyether coolant and gallium indium tin liquid metal microdroplets uniformly dispersed in the perfluoropolyether coolant. The liquid-cooled microtubes are filled with highly thermally conductive nanofluid. The sensing microtubes and liquid-cooled microtubes are respectively designed in parallel to form a sensing channel and a temperature control channel. The inlet and outlet of the sensing channel and the temperature control channel are located at the cable end and are integrated with a dual-cavity micro piezoelectric pump and a dual-cavity micro heat sink to form a sensing array and a temperature control array. The dual-cavity micro piezoelectric pump integrates an embedded edge controller electrically connected to the sensing microtubes.

[0007] Furthermore, both the inner and outer insulating layers are made of nano-composite ceramicized silicone rubber material.

[0008] Furthermore, 5% of a first thermochromic microcapsule and a second thermochromic microcapsule are added to the inner and outer insulating layers, respectively. The first thermochromic microcapsule undergoes a reversible color change in the temperature range of 80~110℃, and the second thermochromic microcapsule undergoes a reversible color change in the temperature range of 90~120℃.

[0009] Furthermore, both the inner and outer insulation layers contain 25% boron nitride thermally conductive filler.

[0010] Furthermore, the fire-resistant layer includes a fire-resistant barrier layer, an intermediate reinforcement layer, and an outer flame-retardant layer arranged sequentially from the inside out. The fire-resistant barrier layer is a ceramicized silicone rubber tape, the intermediate reinforcement layer is an alkali-free glass fiber cloth impregnated with 15% flux, and the outer flame-retardant layer is a nano-composite metal hydrate flame-retardant tape.

[0011] Furthermore, the sheath layer comprises a bottom layer, an intermediate layer, and a top layer arranged sequentially from the inside out. The bottom layer is a modified polyurethane matrix, the intermediate layer is a modified polyurethane with added silicon carbide whiskers, and the top layer is a modified polyurethane with added nano-titanium dioxide, forming a micro-nano composite structure. The nano-titanium dioxide is anchored to the whisker tips of the micro-nano composite structure, and the non-whisker regions of the micro-nano composite structure are coated with an extremely thin layer of fluorosilane.

[0012] Furthermore, the electromagnetic shielding layer includes an aluminum foil longitudinal wrapping layer disposed in the inner layer and a tin-plated copper wire braided layer wrapped around the aluminum foil longitudinal wrapping layer.

[0013] Furthermore, the conductor is made of ultra-fine oxygen-free copper wire, which is formed by three layers of twisting.

[0014] Furthermore, it also includes RFID chips, which are embedded in the sheath layer at intervals along the length of the cable.

[0015] A method for preparing the omni-sensing intelligent temperature control cable as described above includes the following steps: Step S1: Conductor processing, using fine oxygen-free copper wire, twisted alternately in the forward and reverse directions to form a three-layer stranded structure of the conductor, and then annealed at a temperature of 350~400℃ for 2 hours; Step S2: Inner insulation layer manufacturing: The ceramicized silicone rubber material premixed with the first thermochromic microcapsule and boron nitride is extruded onto the conductor through a twin-screw extruder. The temperature is divided into feeding section 80℃, plasticizing section 110℃, homogenizing section 130℃, and die head 125℃, and then subjected to segmented vulcanization treatment at 180℃×90s. Step S3: Fabrication of the intelligent sensing response layer. Using a dual-channel parallel ultraviolet lithography process, sensing microtubes and liquid-cooled microtubes that meet the design requirements are fabricated on a polyimide composite tape substrate. Using a dual-channel vacuum injection system, perfluoropolyether coolant, gallium indium tin liquid metal droplet mixture, and high thermal conductivity nanofluid are injected into the sensing microtubes and liquid-cooled microtubes respectively under an environment of ≤5Pa. The microtubes are then sealed using a pulsed laser welding process. Step S4: Wrapping the intelligent sensing response layer and integrating it with the liquid cooling system. The intelligent sensing response layer prefabricated in step S3 is spirally wrapped around the inner insulation layer, with an alternating wrapping angle of ±10° and an overlap rate of 30%. At one end of the cable manufacturing length, a dual-cavity micro piezoelectric pump and a dual-cavity micro aluminum heat sink are integrated using micro-connection technology. The other end is integrated with a return interface and subjected to cyclic testing. Step S5: Co-extrusion of the outer insulation layer. The ceramicized silicone rubber material premixed with the second thermochromic microcapsule and boron nitride is extruded onto the outside of the intelligent sensing response layer through a twin-screw extruder. The interface temperature is controlled at 135±3℃ by infrared heating to ensure molecular-level fusion of the inner and outer insulation layers. Step S6: Collaborative fire-resistant layer assembly, using a vision-guided automatic wrapping system, with the wrapping angle controlled at 35±1°, precisely wrapping three layers of fire-resistant material in sequence, wherein the fire-resistant barrier layer is a ceramicized silicone rubber tape, the middle reinforcing layer is an alkali-free glass fiber cloth impregnated with 15% flux, and the outer flame-retardant layer is a nano-composite metal hydrate flame-retardant tape. Step S7: Electromagnetic shielding layer processing. The inner layer uses aluminum foil longitudinal wrapping, and ultrasonic welding is used to ensure an overlap width of ≥5mm and 100% coverage. The outer layer uses a 24-spindle braiding machine to braid tin-plated copper wire at high speed, with a braiding angle of 45±1° and a coverage rate of ≥96%. Step S8: Self-cleaning sheath layer gradient manufacturing. The functional gradient sheath is manufactured using a three-layer co-extrusion technology. The inner extruder extrudes the bottom layer modified polyurethane matrix at an extrusion temperature of 170°C. The middle extruder extrudes the modified polyurethane with silicon carbide whiskers at an extrusion temperature of 175°C. The outer extruder extrudes the modified polyurethane with nano-titanium dioxide at an extrusion temperature of 180°C. Cooling is achieved using a three-stage warm water bath: the first stage is 60°C, the second stage is 45°C, and the third stage is 25°C. Step S9: Intelligent system integration and calibration. Install micro-sensor groups at both ends of the cable and every 0.5m. The micro-sensor groups include temperature sensors, pressure sensors and flow sensors. Perform system calibration on temperature, pressure and flow respectively, establish a database, and train a fault diagnosis algorithm based on deep learning. The algorithm includes ≥200,000 sets of data containing fault scenarios such as pressure, cutting, overheating and overload to determine the fault type and perform functional verification. Step S10: Digital quality traceability. RFID chips are implanted every 3 meters of cable to record process parameters, material batch information, and test calibration data throughout the entire manufacturing process.

[0016] By adopting the above technical solution, the present invention has the following beneficial effects: (1) This invention innovatively constructs a continuous monitoring system based on an intelligent sensing response layer inside the cable. It receives the electrical signals of the sensing microtubes through an embedded edge controller and controls the operation of a dual-chamber micro piezoelectric pump to achieve on-demand heat dissipation and reduce energy consumption. It achieves full-domain sensing through the microtube channel array in the polyimide composite tape. It utilizes the multi-physics response characteristics of perfluoropolyether coolant and gallium indium tin liquid metal droplets to achieve centimeter-level precise positioning (±3cm) of various faults such as extrusion, cutting, and overheating. The fault identification accuracy is ≥98%, and the early warning response time is ≤30ms. The liquid cooling system formed by the sensing microtubes and liquid cooling microtubes can increase the current carrying capacity of the cable by 110% under the same cross-sectional area, or reduce the conductor temperature by 20℃ under the same current carrying capacity.

[0017] (2) The inner and outer insulation layers on both sides of the intelligent sensing response layer of this invention are made of nano-composite ceramicized silicone rubber material. The phase change characteristics of nano-composite ceramicized silicone rubber are innovatively used to provide the best support environment for the reconstruction of liquid metal pathway. The embedded edge controller provides pulse signals to the cable damage point through the sensing microtube. Based on the circuit self-repair of the dynamic reconstruction of liquid metal droplets, the rapid repair of the sensing array after damage is realized, thereby realizing the technological leap from "passive protection" to "active survival".

[0018] (3) The inner and outer insulation layers of the present invention integrate reversible thermochromic microcapsules at 80~110℃ and 90~120℃ respectively, so as to realize the visual gradient early warning of temperature anomalies. When the abnormal range of the cable is detected in daily inspection, the abnormal point can be quickly locked, thus improving the maintenance efficiency.

[0019] (4) By adding boron nitride thermally conductive filler into the insulation layer, the present invention solves the problem of the conductor in the center of the cable quickly transferring heat to the intelligent sensing response layer, realizing rapid response and heat dissipation. At the same time, the outer insulation layer can help dissipate some heat from the cable surface. In addition, the high thermal conductivity insulation layer accelerates the diffusion of heat from the damage point, avoids overheating and burning, maintains the temperature stability of the phase change zone, and improves the repair success rate.

[0020] (5) The present invention provides the best protective environment for the internal intelligent sensing response layer through the three-layer synergy of the fire-resistant layer. The ceramicized silicone rubber strip forms an excellent fire-resistant barrier, the alkali-free glass fiber cloth provides mechanical support, and the nano-composite metal hydrate flame-retardant strip decomposes and absorbs heat at 200~400℃, which slows down the temperature rise. The three layers work together to slow down the temperature rise rate in the early stage of fire or local overheating, so that the sensing microtube has enough time to complete damage detection and trigger repair, and avoids the liquid metal from oxidizing and failing due to rapid heating.

[0021] (6) The sheath layer of the present invention is designed with gradient by photocatalysis of nano-titanium dioxide and enhancement of silicon carbide whiskers. The silicon carbide whiskers in the middle layer significantly enhance the anti-cutting and anti-puncture performance and improve the wear resistance by at least 5 times. The micron-sized silicon carbide whiskers serve as a supporting skeleton, forming a rough structure similar to a "forest". The needle-shaped silicon carbide whiskers form an uneven shape on the modified polyurethane matrix. Nano-titanium dioxide is selectively loaded on the top or high point of the whiskers to ensure that they are exposed to the environment, can be exposed to light and contact pollutants. The recessed area of ​​the modified polyurethane matrix is ​​modified with ultra-thin fluorosilane (only covering the non-TiO2 area) to reduce the overall surface energy. When water droplets fall on the surface, they mainly contact the air, the high point of TiO2 and the fluorinated modified polyurethane matrix to achieve Cassie-Baxter state hydrophobicity (contact angle >130°). When exposed to light, the exposed TiO2 can still generate active oxygen to decompose the organic matter attached to it. When rainwater washes it, the water droplets roll off and carry away the degraded dirt, achieving self-cleaning.

[0022] (7) The present invention adopts a double-layer shielding structure formed by longitudinal wrapping of aluminum foil and tin-plated copper wire weaving to achieve excellent shielding effect.

[0023] (8) The conductor of the present invention is formed by stranding three layers of ultra-fine oxygen-free copper wire, achieving excellent flexibility and bending resistance.

[0024] (9) By embedding an RFID chip in the cable, the present invention facilitates the recording of process parameters, material batch information, test calibration data, etc. throughout the manufacturing process, thereby enabling full life cycle quality traceability and predictive maintenance support. Attached Figure Description

[0025] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings, wherein: Figure 1 This is a schematic diagram of the structure of the present invention.

[0026] The labels in the attached diagram are: Conductor 1, Inner Insulation Layer 2, Intelligent Sensing Response Layer 3, Polyimide Composite Tape 3-1, Sensing Microtube 3-2, Liquid-Cooled Microtube 3-3, Outer Insulation Layer 4, Fire-Resistant Layer 5, Electromagnetic Shielding Layer 6, Sheath Layer 7, Bottom Layer 7-1, Intermediate Layer 7-2, Surface Layer 7-3. Detailed Implementation

[0027] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods.

[0028] like Figure 1 The illustrated omnidirectional sensing intelligent temperature control cable includes, from the inside out, a conductor 1, an inner insulation layer 2, an intelligent sensing response layer 3, an outer insulation layer 4, a fire-resistant layer 5, an electromagnetic shielding layer 6, and a sheath layer 7. The intelligent sensing response layer comprises a polyimide composite tape 3-1 and sensing microtubes 3-2 and liquid-cooled microtubes 3-3 embedded within the polyimide composite tape 3-1 and evenly spaced circumferentially. The sensing microtubes 3-2 are filled with perfluoropolyether coolant and gallium indium tin liquid metal droplets uniformly dispersed within the perfluoropolyether coolant. The liquid-cooled microtubes 3-3 are filled with highly thermally conductive nanofluid. The sensing microtubes 3-2 and liquid-cooled microtubes 3-3 are connected in parallel to form the sensing... The inlet and outlet of the sensing and temperature control channels are located at the cable ends and are integrated with a dual-cavity micro piezoelectric pump and a dual-cavity micro heat sink, forming a sensing array and a temperature control array. The dual-cavity micro piezoelectric pump integrates an embedded edge controller that is electrically connected to the sensing microtube 3-2. The embedded edge controller receives the electrical signal from the sensing microtube 3-2 and controls the operation of the dual-cavity micro piezoelectric pump to achieve on-demand heat dissipation and reduce energy consumption. The microtube channel array in the polyimide composite tape achieves full-domain sensing. By utilizing the multi-physics response characteristics of perfluoropolyether coolant and gallium indium tin liquid metal microdroplets, centimeter-level precise positioning of various faults such as extrusion, cutting, and overheating is achieved.

[0029] Specifically, conductor 1 is formed by stranding 99.99% pure ultrafine oxygen-free copper wire in three layers. The diameter of a single copper wire is 0.08mm, with 7 copper wires in the inner layer, 12 copper wires in the middle layer, and 18 copper wires in the outer layer.

[0030] Both the inner insulation layer 2 and the outer insulation layer 4 are made of nano-composite ceramicized silicone rubber material with 25% boron nitride thermally conductive filler. The inner insulation layer 2 contains 5% first thermochromic microcapsules, and the outer insulation layer 4 contains 5% second thermochromic microcapsules. The first thermochromic microcapsules exhibit reversible color changes in the temperature range of 80-110℃, and the second thermochromic microcapsules exhibit reversible color changes in the temperature range of 90-120℃, enabling a visual gradient early warning of temperature anomalies. When an abnormal cable range is detected during routine inspections, the abnormal point can be quickly located, improving maintenance efficiency. The addition of boron nitride thermally conductive filler solves the problem of rapid heat transfer from the conductor 1 at the center of the cable to the intelligent sensing response layer, achieving rapid response and heat dissipation. Simultaneously, the outer insulation layer 4 helps dissipate some heat from the cable surface. Furthermore, the high thermal conductivity insulation layer accelerates heat diffusion from the damage point, preventing overheating and burn-out, maintaining temperature stability in the phase transition zone, and improving the repair success rate.

[0031] The sensing microtubes 3-2 consist of 12 tubes, each 0.3 mm in diameter, filled with gallium indium tin liquid metal droplets with a particle size of 5–20 μm and a volume concentration of 28 ± 1%. The liquid-cooled microtubes 3-3 have a hexagonal cross-section and an outer diameter of 0.6 mm. They are filled with a highly thermally conductive nanofluid, which is a perfluoropolyether-based material containing 10% nano-alumina particles, increasing the thermal conductivity to 0.3 W / (m·K), thus forming an active liquid-cooled circulation system.

[0032] The fire-resistant layer 5 comprises, from the inside out, a fire-resistant barrier layer, an intermediate reinforcement layer, and an outer flame-retardant layer. The fire-resistant barrier layer is a ceramicized silicone rubber strip with a thickness of 0.2 mm and a residual carbon rate of ≥80%. The intermediate reinforcement layer is an alkali-free glass fiber cloth impregnated with 15% flux with a thickness of 0.15 mm. The outer flame-retardant layer is a nano-composite metal hydrate flame-retardant strip with a thickness of 0.3 mm. The ceramicized silicone rubber strip forms an excellent fire-resistant barrier, the alkali-free glass fiber cloth provides mechanical support, and the nano-composite metal hydrate flame-retardant strip absorbs heat during decomposition at 200~400℃, slowing down the temperature rise. The three layers work synergistically; in the early stages of a fire or localized overheating, the fire-resistant layer slows down the rate of temperature rise, allowing the sensing microtubes 3-2 sufficient time to complete damage detection and trigger repair, preventing the liquid metal from oxidizing and failing due to rapid heating.

[0033] The electromagnetic shielding layer 6 includes an inner aluminum foil longitudinal wrapping layer and a tin-plated copper wire braided layer wrapped around the aluminum foil longitudinal wrapping layer. The thickness of the aluminum foil longitudinal wrapping layer is 0.1 mm, with a coverage of 100%, and the coverage of the tin-plated copper wire braided layer is 95%, achieving excellent shielding effect and ensuring shielding effectiveness ≥70dB (30MHz-1GHz).

[0034] The sheath layer 7 comprises, from the inside out, a bottom layer 7-1, an intermediate layer 7-2, and a top layer 7-3. The bottom layer 7-1 is a modified polyurethane matrix, ensuring basic flexibility. The intermediate layer 7-2 is a modified polyurethane with 2% silicon carbide whiskers added, and the top layer 7-3 is a modified polyurethane with 3% nano-titanium dioxide added, forming a micro-nano composite structure. The nano-titanium dioxide is anchored at the whisker tips of the micro-nano composite structure, and the non-whisker areas of the micro-nano composite structure are coated with an extremely thin layer of fluorosilane. The modified polyurethane satisfies strong adhesion and high elasticity, and has good flowability at 170°C. Examples include high-performance TPU with polycarbonate diol as the soft segment, MDI as the isocyanate, chain extenders containing silane coupling agents, and the HALS anti-aging system. The silicon carbide whiskers in the intermediate layer 7-2 significantly enhance the resistance to cutting and puncture, and improve wear resistance by at least 5 times. The micron-sized silicon carbide whiskers serve as a supporting framework, forming a rough structure similar to a "forest". The needle-like silicon carbide whiskers form an uneven surface on the modified polyurethane matrix. Nano-titanium dioxide is selectively loaded on the tips or high points of the whiskers to ensure that they are exposed to the environment, can accept light and contact pollutants. The recessed areas of the modified polyurethane matrix are modified with ultrathin fluorosilane (only covering non-TiO2 areas) to reduce the overall surface energy. This constructs a scheme that combines a micro-nano dual-scale rough structure with selective surface energy regulation, achieving a contact angle >130°, high hydrophobicity, and retaining the photocatalytic activity of TiO2. When water droplets fall on the surface, they mainly come into contact with air, TiO2 high points, and fluorinated modified polyurethane matrix, achieving Cassie-Baxter hydrophobicity. When exposed to light, the exposed TiO2 can still generate active oxygen, decomposing organic matter attached to it. When rainwater washes it off, the water droplets roll off and carry away the degraded dirt, achieving self-cleaning.

[0035] To enable full lifecycle quality traceability and predictive maintenance support, this embodiment also includes an RFID chip. The RFID chip is embedded in the sheath layer 7 every 3 meters along the cable length to record process parameters, material batch information, test calibration data, etc. throughout the manufacturing process.

[0036] This embodiment also provides a method for the above-mentioned all-area sensing intelligent temperature control cable, including the following steps: Step S1: Conductor 1 is processed using fine oxygen-free copper wire, which is twisted alternately in both directions, with the inner layer twisted clockwise to form a three-layer stranded structure. The tension is monitored in real time by a tension monitoring system, with a tension control accuracy of ±0.5N. The pitch ratios of the three layers are 10, 12, and 14, respectively, to ensure excellent flexibility and bending resistance. After stranding, the conductor is annealed at a temperature of 350~400℃ for 2 hours to ensure a bending life of >8 million cycles. Step S2: Inner insulation layer manufacturing. The ceramicized silicone rubber material premixed with the first thermochromic microcapsule and boron nitride is extruded onto the conductor using a twin-screw extruder. The premixing equipment is an internal mixer at a temperature of 80°C. The particle size of the first thermochromic microcapsule is 8~15μm. The extrusion temperature is divided into four sections: feeding section 80°C, plasticizing section 110°C, homogenizing section 130°C, and die head 125°C, to ensure that the thermochromic microcapsule is not damaged. The thickness is precisely controlled within the range of 0.8~1.2mm with a tolerance of ±0.03mm. The material is then subjected to a segmented vulcanization treatment at 180°C for 90s to ensure that the insulation layer is completely cured and the color-changing performance is stable. Step S3: Fabrication of the intelligent sensing response layer. Sensing microtubes and liquid-cooled microtubes meeting design requirements were fabricated on a polyimide composite substrate using a dual-channel parallel ultraviolet lithography process. A dual-channel vacuum injection system was used to inject a mixture of perfluoropolyether coolant, gallium indium tin liquid metal droplets, and a high thermal conductivity nanofluid into the sensing and liquid-cooled microtubes at an environment ≤5 Pa. The high thermal conductivity nanofluid has a thermal conductivity of 0.3 W / (m·K), and the injection pressure was 0.12±0.02 MPa. Visual monitoring was used to ensure no air bubbles were present. The microtubes were then sealed using a pulsed laser welding process with a welding power of 70±5 W and a welding speed of 120±10 mm / s. The weld strength was ≥20 MPa. A pressure test was performed after welding; no leakage was observed after holding the pressure at 0.3 MPa for 30 minutes. Step S4: Wrapping the intelligent sensing response layer and integrating it with the liquid cooling system. The intelligent sensing response layer prefabricated in step S3 is spirally wrapped around the inner insulation layer. The wrapping angle is ±10°, the overlap width is controlled at 1.5mm, the overlap rate is 30%, and the wrapping tension is 6.5±1.5N. During the wrapping process, it is ensured that the liquid cooling microtube and the sensing microtube are evenly distributed. At one end of the cable manufacturing length, a dual-chamber micro piezoelectric pump and a dual-chamber micro aluminum heat sink are integrated using micro-connection technology, while the other end integrates a return interface and undergoes cyclic testing, with a flow stability error of ≤5%. Step S5: Co-extrusion of the outer insulation layer. The ceramicized silicone rubber material premixed with the second thermochromic microcapsule and boron nitride is extruded onto the outside of the intelligent sensing response layer through a twin-screw extruder with a thickness of 0.5~0.8mm. The interface temperature is controlled at 135±3℃ by infrared heating to ensure that the inner and outer insulation layers are fused at the molecular level to form a unified ceramicized protection system. The thermochromic performance is calibrated after co-extrusion. Step S6: Coordinated refractory layer assembly, using a vision-guided automatic wrapping system, with the wrapping angle controlled at 35±1°, precisely wrapping three layers of refractory material in sequence, wherein the refractory barrier layer is a ceramicized silicone rubber tape with a thickness of 0.20±0.02mm and a 50% overlap rate, the middle reinforcing layer is an alkali-free glass fiber cloth impregnated with 15% flux with a thickness of 0.15±0.01mm, and the outer flame retardant layer is a nano-composite metal hydrate flame retardant tape with a thickness of 0.30±0.02mm; Step S7: Electromagnetic shielding layer processing. The inner layer uses aluminum foil longitudinal wrapping, and ultrasonic welding is used to ensure an overlap width of ≥5mm and 100% coverage. The outer layer uses a 24-spindle braiding machine to braid tin-plated copper wire at high speed, with a braiding angle of 45±1° and a coverage rate of ≥96%. The shielding effectiveness is tested online to ensure ≥70dB in the 30MHz-1GHz frequency band and ≥75dB at the key frequency (100MHz). Step S8: Gradient manufacturing of self-cleaning sheath layers. Functional gradient sheaths are manufactured using a three-layer co-extrusion technology, with each layer having a thickness of 0.5mm. The inner extruder extrudes the bottom layer of modified polyurethane matrix at an extrusion temperature of 170℃. The middle extruder extrudes modified polyurethane with added silicon carbide whiskers at an extrusion temperature of 175℃. The outer extruder extrudes modified polyurethane with added nano-titanium dioxide at an extrusion temperature of 180℃. Cooling is achieved using a three-stage warm water bath: the first stage is 60℃ (rapid setting), the second stage is 45℃ (stress release), and the third stage is 25℃ (final cooling). Step S9: Intelligent system integration and calibration. Install micro-sensor groups at both ends of the cable and every 0.5m. The micro-sensor groups include temperature sensors (accuracy ±0.5℃, 4 per meter), pressure sensors (range 0~1MPa, accuracy ±0.2%), and flow sensors (range 0-100mL / min, accuracy ±1%). The temperature, pressure, and flow rate were calibrated separately, and a database was established. The pulse pressure for fluid pressure calibration was 0.08±0.002MPa, the sampling frequency was 2kHz, and a pressure-position mapping database of 512 points / meter was established. The temperature calibration was performed using gradient temperature field testing, and a three-dimensional control model of temperature-color change-flow rate was established. The liquid cooling system calibration was performed by testing the heat dissipation efficiency curves under different flow rates and optimizing the control algorithm. The deep learning-based fault diagnosis algorithm was trained with ≥200,000 sets of data covering fault scenarios such as compression, cutting, overheating, and overload. The fault type was determined, and the fault type identification accuracy was ≥99%, the positioning accuracy was ±2cm, the warning response time was ≤30ms, the self-repair decision time was ≤100ms, and the function was verified. Step S10: Digital quality traceability. RFID chips are implanted every 3 meters of cable to record process parameters, material batch information, and test calibration data throughout the entire manufacturing process.

[0037] This invention innovatively constructs a continuous monitoring system based on intelligent sensing and response layers inside the cable. It achieves full-domain sensing through a micro-channel array in a polyimide composite tape. Utilizing the multi-physics response characteristics of perfluoropolyether coolant and gallium indium tin liquid metal microdroplets, combined with deep learning algorithms, it achieves centimeter-level precise positioning (±3cm) for various faults such as extrusion, cutting, and overheating, with a fault identification accuracy of ≥98% and an early warning response time of ≤30ms.

[0038] Circuit self-repair based on dynamic reconstruction of liquid metal microdroplets innovatively utilizes the phase change characteristics of nanocomposite ceramicized silicone rubber to provide the best support environment for liquid metal path reconstruction. The self-repair response time is ≤150ms, the success rate is ≥92%, and the change rate of path resistance after repair is ≤10%, achieving a technological leap from "passive protection" to "active survival".

[0039] An integrated micro piezoelectric pump circulation system forms a closed liquid-cooled loop, increasing the current carrying capacity of the cable by 110% under the same cross-sectional area, or reducing the conductor operating temperature by more than 20°C under the same current carrying capacity. This makes it perfectly suited for high-density power transmission scenarios such as 800kW high-power charging piles and data centers. It constructs a complete thermal safety system: daily liquid cooling (maintaining <80°C) → emergency phase-change cooling (>229°C vaporization and heat absorption) → ultimate self-healing, completely solving the heat dissipation and safety bottlenecks in high-power applications.

[0040] Through a triple synergistic mechanism of nanocomposite metal hydrate, modified glass fiber cloth, and ceramicized silicone rubber tape, combined with the phase change endothermic effect of perfluoropolyether coolant in the intelligent sensing and response layer, local active cooling of 250~350℃ is achieved. Under extreme conditions of 1100℃ / 3h, it not only maintains structural integrity but also ensures the normal operation of intelligent functions, and improves fire resistance by 50%.

[0041] This cable deeply integrates five major functions: power transmission, status sensing, fault self-repair, intelligent early warning, and liquid cooling. The self-cleaning sheath layer, through a gradient design enhanced by nano-titanium dioxide photocatalysis and silicon carbide whiskers, achieves a contact angle >130° and a 5-fold increase in wear resistance. In complex industrial environments, its service life is more than 3 times that of traditional cables, and its total lifespan cost is reduced by 65%. It fundamentally solves the long-standing contradiction between "power enhancement and heat dissipation safety" in fields such as supercharging, data centers, and high-dynamic robots, and has broad market application prospects.

[0042] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A global sensing intelligent temperature control cable, characterized in that: The device comprises, from the inside out, a conductor, an inner insulation layer, a smart sensing response layer, an outer insulation layer, a fire-resistant layer, an electromagnetic shielding layer, and a sheath layer. The smart sensing response layer includes a polyimide composite tape and sensing microtubes and liquid-cooled microtubes embedded in the polyimide composite tape and evenly spaced along the circumference. The sensing microtubes are filled with perfluoropolyether coolant and gallium indium tin liquid metal microdroplets uniformly dispersed in the perfluoropolyether coolant. The liquid-cooled microtubes are filled with highly thermally conductive nanofluids. The sensing microtubes and liquid-cooled microtubes are designed in parallel to form a sensing channel and a temperature control channel, respectively. The inlet and outlet of the sensing channel and the temperature control channel are located at the cable end and are integrated with a dual-cavity micro piezoelectric pump and a dual-cavity micro heat sink to form a sensing array and a temperature control array. The dual-cavity micro piezoelectric pump integrates an embedded edge controller electrically connected to the sensing microtubes.

2. The all-area sensing intelligent temperature control cable according to claim 1, characterized in that: Both the inner and outer insulation layers are made of nano-composite ceramicized silicone rubber material.

3. The all-area sensing intelligent temperature control cable according to claim 2, characterized in that: The inner and outer insulating layers each contain 5% of a first thermochromic microcapsule and a second thermochromic microcapsule. The first thermochromic microcapsule undergoes a reversible color change in the temperature range of 80~110℃, and the second thermochromic microcapsule undergoes a reversible color change in the temperature range of 90~120℃.

4. The all-area sensing intelligent temperature control cable according to claim 3, characterized in that: Both the inner and outer insulation layers contain 25% boron nitride thermally conductive filler.

5. The all-area sensing intelligent temperature control cable according to claim 1, characterized in that: The fire-resistant layer comprises a fire-resistant barrier layer, an intermediate reinforcement layer, and an outer flame-retardant layer arranged sequentially from the inside out. The fire-resistant barrier layer is a ceramicized silicone rubber tape, the intermediate reinforcement layer is an alkali-free glass fiber cloth impregnated with 15% flux, and the outer flame-retardant layer is a nano-composite metal hydrate flame-retardant tape.

6. The all-area sensing intelligent temperature control cable according to claim 1, characterized in that: The sheath layer comprises a bottom layer, an intermediate layer, and a top layer arranged sequentially from the inside out. The bottom layer is a modified polyurethane matrix, the intermediate layer is a modified polyurethane with added silicon carbide whiskers, and the top layer is a modified polyurethane with added nano-titanium dioxide, forming a micro-nano composite structure. The nano-titanium dioxide is anchored to the whisker tips of the micro-nano composite structure, and the non-whisker regions of the micro-nano composite structure are coated with fluorosilane.

7. The all-area sensing intelligent temperature control cable according to claim 1, characterized in that: The electromagnetic shielding layer includes an inner aluminum foil longitudinal layer and a tin-plated copper wire braided layer wrapped around the aluminum foil longitudinal layer.

8. The all-area sensing intelligent temperature control cable according to claim 1, characterized in that: The conductor is made of ultra-fine oxygen-free copper wire, which is formed by three layers of twisting.

9. The all-area sensing intelligent temperature control cable according to claim 1, characterized in that: It also includes RFID chips, which are embedded in the sheath layer at intervals along the length of the cable.

10. A method for preparing a global sensing intelligent temperature control cable as described in any one of claims 1 to 9, characterized in that, Includes the following steps: Step S1: Conductor processing, using fine oxygen-free copper wire, twisted alternately in the forward and reverse directions to form a three-layer stranded structure of the conductor, and then annealed at a temperature of 350~400℃ for 2 hours; Step S2: Inner insulation layer manufacturing: The ceramicized silicone rubber material premixed with the first thermochromic microcapsule and boron nitride is extruded onto the conductor through a twin-screw extruder. The temperature is divided into feeding section 80℃, plasticizing section 110℃, homogenizing section 130℃, and die head 125℃, and then subjected to segmented vulcanization treatment at 180℃×90s. Step S3: Fabrication of the intelligent sensing response layer. Using a dual-channel parallel ultraviolet lithography process, sensing microtubes and liquid-cooled microtubes that meet the design requirements are fabricated on a polyimide composite tape substrate. Perfluoropolyether coolant, gallium indium tin liquid metal droplet mixture, and high thermal conductivity nanofluid are injected into the sensing microtubes and liquid-cooled microtubes respectively in an environment of ≤5Pa through a dual-channel vacuum injection system. The microtubes are then sealed using a pulsed laser welding process. Step S4: Wrapping the intelligent sensing response layer and integrating it with the liquid cooling system. The intelligent sensing response layer prefabricated in step S3 is spirally wrapped around the inner insulation layer, with an alternating wrapping angle of ±10° and an overlap rate of 30%. At one end of the cable manufacturing length, a dual-cavity micro piezoelectric pump and a dual-cavity micro aluminum heat sink are integrated using micro-connection technology. The other end is integrated with a return interface and subjected to cyclic testing. Step S5: Co-extrusion of the outer insulation layer. The ceramicized silicone rubber material premixed with the second thermochromic microcapsule and boron nitride is extruded onto the outside of the intelligent sensing response layer through a twin-screw extruder. The interface temperature is controlled at 135±3℃ by infrared heating to ensure molecular-level fusion of the inner and outer insulation layers. Step S6: Collaborative fire-resistant layer assembly, using a vision-guided automatic wrapping system, with the wrapping angle controlled at 35±1°, precisely wrapping three layers of fire-resistant material in sequence, wherein the fire-resistant barrier layer is a ceramicized silicone rubber tape, the middle reinforcing layer is an alkali-free glass fiber cloth impregnated with 15% flux, and the outer flame-retardant layer is a nano-composite metal hydrate flame-retardant tape. Step S7: Electromagnetic shielding layer processing. The inner layer uses aluminum foil longitudinal wrapping, and ultrasonic welding is used to ensure an overlap width of ≥5mm and 100% coverage. The outer layer uses a 24-spindle braiding machine to braid tin-plated copper wire at high speed, with a braiding angle of 45±1° and a coverage rate of ≥96%. Step S8: Self-cleaning sheath layer gradient manufacturing. The functional gradient sheath is manufactured using a three-layer co-extrusion technology. The inner extruder extrudes the bottom layer modified polyurethane matrix at an extrusion temperature of 170°C. The middle extruder extrudes the modified polyurethane with silicon carbide whiskers at an extrusion temperature of 175°C. The outer extruder extrudes the modified polyurethane with nano-titanium dioxide at an extrusion temperature of 180°C. Cooling is achieved using a three-stage warm water bath: the first stage is 60°C, the second stage is 45°C, and the third stage is 25°C. Step S9: Digital quality traceability. RFID chips are implanted every 3 meters of cable to record process parameters, material batch information, and test calibration data throughout the entire manufacturing process.

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