15MPa longitudinal watertight high-flexibility temperature-resistant cabin-penetrating cable and manufacturing method thereof

Abstract

The invention belongs to the technical field of longitudinal watertight cables, and discloses a 15Mpa longitudinal watertight high-flexibility temperature-resistant cabin-penetrating cable and a manufacturing method thereof. According to the invention, through the design of a watertight stranded conductor with a special structure, the extrusion of a composite insulating layer, the unit type cabling, the re-stranding cabling of each sub-cabling unit, the armored combination of a breathable non-woven wrapping tape and a semi-solid high-temperature-resistant sealant, the sheath layer and the like; the cable has the advantages of 15MPa longitudinal watertightness, 0.5 MPa longitudinal airtightness, resistance to the ultimate low temperature of-54 DEG C, 125 DEG C compatibility, dripping resistance at 95 DEG C, alternating water pressure resistance (0-15MPa-0), long-term seawater corrosion resistance, liquid immersion resistance, salt mist resistance, humidity and heat resistance, mold resistance, core breakage after 3D-4D (D is the diameter of the cable) multiple times of bending, sunlight radiation resistance, electrical performance and watertightness performance after circulation at the temperature of-54 DEG C to 90 DEG C, vibration, inclination and swinging, and the like. Bumping and cabin penetrating reliability and the like are achieved.

Description

Technical Field

[0001] This invention relates to the field of longitudinal watertight cable technology, and in particular to a 15MPa longitudinal watertight high-flexibility and high-temperature resistant cable with a canopy and its manufacturing method. Background Technology

[0002] Longitudinal watertight cables are mainly used for installation outside equipment compartments or through pressure-resistant hulls to achieve electrical connections between equipment inside the ship and equipment outside the hull. Currently, underwater vessel equipment is increasingly deployed in waters over 1000 meters deep, requiring longitudinal watertight cables to not only possess higher water pressure resistance but also, due to the global navigation characteristics of ships and the variability of the marine environment, exhibit environmental adaptability and reliability beyond just longitudinal watertightness. This includes longitudinal airtightness at 0.5 MPa, resistance to extreme low temperatures of -54℃, high-temperature compatibility at 125℃, repeated water pressure cycling (0~15 MPa~0), long-term resistance to seawater corrosion, salt spray, damp heat, and mold, flexibility without core breakage, resistance to sunlight aging, temperature cycling from -54℃ to 90℃, and subsequent electrical and watertight performance and reliability through hulls. These measures ensure the long-term safety of the cable's service life and avoid the risk of seal failure at the cable end face, cable sheath, and between the cable and hull-penetrating components.

[0003] While existing technologies offer various solutions for longitudinal watertight cables, they only focus on certain performance aspects, such as longitudinal watertightness, high-temperature vulcanization performance, and penetration sealing or bending performance. They fail to demonstrate all the overall performance characteristics requested by the end-market and users, thus failing to fully address customer pain points. Corresponding watertight filling structure technologies for longitudinal watertight cables can be mainly summarized as rigid adhesive filling, soft adhesive filling, and water-swellable material filling.

[0004] Rigid filler is achieved by injecting high-temperature molten adhesive or room-temperature paste-like water-blocking adhesive between conductors, cores, or braided gaps, which solidifies completely over time to block water. The advantage of this process is that the cable is less prone to deformation under pressure. The disadvantages are that the cured filler cable is too stiff, difficult to bend, and may have poor filling of braided gaps, leading to watertightness failure, electrical performance failure, or core breakage due to bending.

[0005] Soft adhesive filler is used to achieve longitudinal sealing by filling the gaps between conductor filaments and cores with highly viscous, soft, self-adhesive adhesive. Its advantages include good cable flexibility, and good filling and maintenance of the filler between the filler and copper wires when bent. Disadvantages include the cable's tendency to deform and become difficult to secure during cable packing, making sealing between the filler and stuffing box challenging; and the potential for filler leakage and dripping when the cable heats up during operation, reducing watertightness.

[0006] Water-swellable filling involves filling the gaps between cable structural components with water-swellable yarn, water-swellable powder, or wrapping with water-swellable tape. These materials expand rapidly upon contact with water, filling the confined space to form a water flow barrier and seal it. Its advantages include excellent longitudinal water-blocking performance, high cable flexibility, no paste-like leakage from the ends, and ease of assembly and installation. Disadvantages include the cable's susceptibility to deformation and difficulty in securing it during cable packing, as well as difficulties in sealing the cable with the stuffing box; and the inability of the water-blocking fibers to repeatedly expand, affecting its service life.

[0007] Given the defects and shortcomings of existing technologies, longitudinal watertight cables frequently experience various failures in practical applications, seriously affecting the safety and service life of equipment systems. Various attempts have begun in the industry, such as CN112908541B, which discloses a high-temperature vulcanized longitudinal watertight cable and stranding mold, aiming to allow high-temperature vulcanization of the cable. From the examples and comparative examples, it can be seen that a longitudinal watertight performance of 10MPa is achieved, meeting the requirements of GJB1916-94, but it does not possess a longitudinal watertight performance of 15MPa. It also fails to achieve resistance to extreme low temperatures of -54℃, compatibility at 125℃, drip resistance at 95℃, resistance to oil stains, salt spray, damp heat, mold, multiple bending without core breakage (3D~4D, where D is the cable diameter), resistance to sunlight radiation, and electrical and watertight performance after temperature cycling from -54℃ to 90℃, as well as reliability against vibration, tilting and swaying, turbulence, and penetration. CN118165672A discloses a halogen-free longitudinal watertight cable sealant and its preparation method. By modifying polyisobutylene, it achieves adhesion and flexural flowability between components, aiming to solve the problem of cable flexibility while ensuring 10MPa longitudinal watertightness and 0.3MPa longitudinal airtightness. However, based on the operating temperature in the preparation process, it also lacks the required performance for 15MPa longitudinal watertightness, resistance to extreme low temperatures of -54℃, compatibility at 125℃, drip resistance at 95℃, electrical and watertight performance after temperature cycling from -54℃ to 90℃, and reliability against vibration, tilting and swaying, turbulence, and tank penetration. CN108172330B discloses a longitudinal watertight cable, focusing only on the longitudinal watertightness of the cable and failing to meet the reliability performance requirements under the aforementioned environmental adaptability conditions. CN118675802A discloses a longitudinally watertight rubber-sheathed cable resistant to 64MPa seawater pressure. While a stainless steel plate support frame is incorporated into the cable structure to increase radial water pressure resistance, this sacrifices bending performance and fails to meet the flexibility requirements of cables within the confined spaces of shipboard equipment. Other similar technical solutions also fail to achieve the overall performance required based on the actual operating conditions of the equipment or system, exhibiting significant shortcomings. Furthermore, the watertight adhesive between the conductor filaments in existing technologies is all insulating adhesive, leading to increased overall conductor resistance, higher heat generation and temperature rise during application, thus affecting current carrying capacity and service life. Summary of the Invention

[0008] To overcome the shortcomings of existing technologies, this invention provides a 15MPa longitudinal watertight, highly flexible, and temperature-resistant cable for use in cabins, along with its manufacturing method. Through a special structural watertight stranded conductor design, extruded composite insulation layer, unitized cabling, re-stranding of each branch cabling unit, combination of breathable non-woven tape and semi-solid high-temperature resistant sealant armor, and sheath layer, the aim is to enable the cable to possess 15MPa longitudinal watertightness, 0.5MPa longitudinal airtightness, resistance to extreme low temperatures of -54℃, 125℃ compatibility, 95℃ drip resistance, resistance to alternating water pressure (0~15MPa~0), long-term resistance to seawater corrosion, liquid immersion, salt spray, damp heat, and mold resistance; 3D~4D (D is the cable diameter) repeated bending without core breakage; resistance to sunlight radiation; and electrical and watertight performance, vibration, tilting and swaying, shock absorption, and cabin reliability after temperature cycling from -54℃ to 90℃.

[0009] To achieve the above objectives, the present invention provides a 15MPa longitudinal watertight, highly flexible, and temperature-resistant cable with a canopy, comprising a stranded watertight conductor, a composite insulation layer, a first breathable nonwoven tape, a reinforcing filler core, a shaped filler core, a high-viscosity, low-hardness sealant, a second breathable nonwoven tape, braided armor, a semi-solid high-temperature resistant sealant, and a sheath layer. A composite insulation layer is applied to the outside of a watertight stranded conductor. Several watertight stranded conductors with composite insulation layer are stranded together to form a cable unit. High-viscosity, low-hardness sealant is filled between the watertight stranded conductors with composite insulation layer. The cable unit is wrapped with a first breathable non-woven tape. Each cable unit wrapped with the first breathable nonwoven tape is twisted together to form an assembly cable. A shaped filler core is set in the center of the assembly cable, and a reinforcing filler core is set in the gap around the cable core of the assembly cable. High-viscosity, low-hardness sealant is filled between each cable unit, the shaped filler core, and the reinforcing filler core. The assembly cable is wrapped with a second breathable nonwoven tape. The second breathable non-woven strap is woven with tin-plated copper single wire to form armor, and the gaps in the armor are filled with semi-solid high-temperature resistant sealant. The woven armor has an outer sheath layer, which is a double-layer composite sheath.

[0010] Furthermore, the watertight stranded conductor uses 19 or 37 tinned copper single wires concentrically stranded, arranged in a pattern of 1+6+12 and 1+6+12+18 from the center outwards, with a stranding pitch ratio of 8-12 times.

[0011] Furthermore, the watertight stranded conductor includes tin-plated copper single wire, a highly elastic conductive layer, and a highly viscous, low-hardness conductive sealant. The tin-plated copper single wire at the center is extruded with a high-elasticity conductive layer. The outer periphery of the high-elasticity conductive layer has a concave arc-shaped regular hexagonal irregular structure. The side length is equal to the cross-sectional diameter of the tin-plated copper single wire on its periphery. The extrusion thickness at the apex of the concave arc ranges from 0.10mm to 0.20mm. The length of the concave arc is one-quarter of the cross-sectional perimeter of the tin-plated copper single wire, so that there are uniform gaps between the tin-plated copper single wires when the first layer of conductors is stranded. When the second and third conductors outside the first conductor are stranded, each tinned copper wire is placed in the gap formed by adjacent tinned copper wires inside. During stranding, the gaps between the tinned copper wires are filled with high-viscosity, low-hardness conductive sealant.

[0012] Furthermore, the composite insulation layer adopts a double-layer composite structure, including an inner composite insulation layer and an outer composite insulation layer. The inner composite insulation layer is made of 125℃ low-density polyethylene, and the outer composite insulation layer is made of 150℃ cross-linked polyethylene. During extrusion, the outer composite insulation layer is passivated by using a serrated abrasive.

[0013] Furthermore, the number of watertight stranded conductors covered with composite insulation in the cable unit is 3-5, and the section diameter ratio is 8-12 times.

[0014] Furthermore, the surface of the first breathable nonwoven wrapping tape is provided with uniformly distributed perforations, the wrapping overlap rate is 5%-15%, and the thickness is 0.03mm-0.07mm.

[0015] Furthermore, the sheath layer is a double-layer composite sheath, with the inner layer made of ethylene vinyl acetate and the outer layer made of chlorosulfonated polyethylene or polyether polyurethane compound.

[0016] This invention also provides a method for manufacturing a 15MPa longitudinal watertight, highly flexible, and heat-resistant cable with a canopy, comprising the following steps: Step 1: Form a watertight stranded conductor; Step 1.1: Use 19 or 37 tinned copper single wires concentrically twisted together, arranged in a pattern of 1+6+12 and 1+6+12+18 from the center outwards, with a twisting pitch ratio of 8-12 times; Step 1.2: A watertight stranded conductor is formed by tin-plated copper single wires, a high-elasticity conductive layer, and a high-viscosity, low-hardness conductive sealant. The tin-plated copper single wire at the center is surrounded by a high-elasticity conductive layer. The outer periphery of the high-elasticity conductive layer has a concave arc-shaped regular hexagonal irregular structure. The side length is equal to the diameter of the tin-plated copper single wire cross-section. The extrusion thickness at the apex of the concave arc ranges from 0.10mm to 0.20mm. The length of the concave arc is one-quarter of the circumference of the tin-plated copper single wire cross-section, so that a uniform gap appears between the tin-plated copper single wires when the first layer of conductors is stranded. When the second and third conductors outside the first conductor are twisted together, each tinned copper wire is placed in the gap formed by adjacent tinned copper wires inside. When twisting, the gaps between the tinned copper wires are filled with high-viscosity, low-hardness conductive sealant. Step 2: Composite insulation: The composite insulation layer adopts a double-layer composite structure, including an inner composite insulation layer and an outer composite insulation layer. The material used for the inner composite insulation layer is 125℃ low-density polyethylene, and the material used for the outer composite insulation layer is 150℃ cross-linked polyethylene. During extrusion, the outer composite insulation layer is passivated by using a serrated abrasive. Step 3: Unit cabling: 3 to 5 watertight stranded conductors covered with composite insulation layer are stranded together to form a cable unit. The pitch ratio is set to 8 to 12 times. High viscosity and low hardness sealant is filled between the watertight stranded conductors covered with composite insulation layer. The cable unit is wrapped with a first breathable non-woven tape. Step 4: Each sub-cable unit is re-twisted into a cable: Each sub-cable unit wrapped with the first breathable non-woven tape is re-twisted into an assembly cable. A special-shaped filler core is set in the center of the assembly cable, and a reinforcing filler core is set in the gap around the cable core of the assembly cable. High-viscosity, low-hardness sealant is filled between each sub-cable unit, the special-shaped filler core, and the reinforcing filler core. The assembly cable is wrapped with a second breathable non-woven tape. Step 5: Weaving armor: The second breathable non-woven strap is woven with tin-plated copper single wire to form armor, and the gaps in the armor are filled with semi-solid high-temperature resistant sealant. Step 6: The woven armor has an outer sheath layer, which is a double-layer composite sheath.

[0017] Furthermore, the surface of the first breathable nonwoven wrapping tape is provided with uniformly distributed perforations, the wrapping overlap rate is 5%-15%, and the thickness is 0.03mm-0.07mm.

[0018] Furthermore, the sheath layer is a double-layer composite sheath, with the inner layer made of ethylene vinyl acetate and the outer layer made of chlorosulfonated polyethylene or polyether polyurethane compound.

[0019] Beneficial effects: The present invention provides a 15MPa longitudinal watertight high-flexibility temperature-resistant cable and manufacturing method, which has the following beneficial effects: (1) Watertight and airtight performance: Through special structure watertight stranded conductor design, extruded composite insulation special appearance, unit structure cable forming, air-permeable non-woven tape and semi-solid high-temperature resistant sealant armor combination, composite structure sheath, etc., the cable achieves 15MPa longitudinal watertight performance with no dripping water at the beginning, sheath displacement not greater than 6.4mm, and 0.5MPa longitudinal airtightness without bubbles. (2) Reliability and environmental adaptability: Based on the longitudinal watertightness of 15MPa and longitudinal airtightness of 0.5MPa, the product can simultaneously achieve the following properties: resistance to -54℃ polar low temperature, 125℃ compatibility, 95℃ drip resistance, electrical performance and longitudinal watertightness after temperature cycling from -54℃ to 90℃, long-term resistance to seawater corrosion, oil stains, salt spray, damp heat, mold, sunlight radiation, resistance to alternating water pressure through-chamber sealing (0~15MPa~0), 3D~4D (D is the cable diameter) bending without core breakage, vibration, tilting and swaying, and shock. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the product structure of a 15MPa longitudinal watertight high-flexibility temperature-resistant cable with a canopy. Figure 2 This is a schematic diagram of a stranded watertight conductor and a composite insulation layer; Explanation of reference numerals in the attached figures: 1 is a stranded watertight conductor; 2 is a composite insulation layer; 3 is a first breathable nonwoven wrapping tape; 4 is a reinforcing filler core; 5 is a shaped filler core; 6 is a high-viscosity, low-hardness sealant; 7 is a second breathable nonwoven wrapping tape; 8 is a braided armor; 9 is a semi-solid high-temperature resistant sealant; 10 is a sheath layer; 1-1 is a single wire; 1-2 is a high-elasticity conductive layer; 1-3 is a high-viscosity, low-hardness conductive sealant; 2-1 is a composite insulation inner layer; 2-2 is a composite insulation outer layer. Detailed Implementation

[0021] The preferred mechanisms and implementation methods of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0022] The properties of the high-elasticity conductive layer 1-2 and the high-viscosity, low-hardness conductive sealant 1-3 are shown in Table 1: .

[0023] The performance indicators of the first and second breathable nonwoven wrapping tapes are shown in Table 2: .

[0024] The performance indicators of the high-viscosity, low-hardness sealant are shown in Table 3: .

[0025] The performance indicators of the reinforced filler core are shown in Table 4: .

[0026] The performance indicators of the semi-solid high-temperature resistant sealant are shown in Table 5: .

[0027] Example 1: Figure 1 This is a schematic diagram of the product structure of a 15MPa longitudinal watertight high-flexibility temperature-resistant cable with a canopy. Figure 2 This is a schematic diagram of a stranded watertight conductor and a composite insulation layer.

[0028] A 15MPa longitudinal watertight, highly flexible, and temperature-resistant cable with a canopy includes a stranded watertight conductor, a composite insulation layer, a first breathable nonwoven tape, a reinforcing filler core, a shaped filler core, a high-viscosity, low-hardness sealant, a second breathable nonwoven tape, braided armor, a semi-solid high-temperature resistant sealant, and a sheath layer. A composite insulation layer is applied to the outside of a watertight stranded conductor. Several watertight stranded conductors with composite insulation layer are stranded together to form a cable unit. High-viscosity, low-hardness sealant is filled between the watertight stranded conductors with composite insulation layer. The cable unit is wrapped with a first breathable non-woven tape. Each cable unit wrapped with the first breathable nonwoven tape is twisted together to form an assembly cable. A shaped filler core is set in the center of the assembly cable, and a reinforcing filler core is set in the gap around the cable core of the assembly cable. High-viscosity, low-hardness sealant is filled between each cable unit, the shaped filler core, and the reinforcing filler core. The assembly cable is wrapped with a second breathable nonwoven tape. The second breathable non-woven strap is woven with tin-plated copper single wire to form armor, and the gaps in the armor are filled with semi-solid high-temperature resistant sealant. The woven armor has an outer sheath layer, which is a double-layer composite sheath.

[0029] Watertight stranded conductor: The watertight stranded conductor uses 19 or 37 tinned copper single wires concentrically stranded, arranged in a 1+6+12 and 1+6+12+18 pattern from the center outwards, with a stranding pitch ratio of 8-12 times to increase the longitudinal water resistance of the filler adhesive. The gaps between the single wires are filled with high-viscosity, low-hardness, and highly conductive sealant.

[0030] The tin-plated copper single wire 1-1 located in the center is surrounded by a high-elasticity conductive layer 1-2, which can ensure the bonding and sealing between the high-elasticity conductive layer and the inner single wire. The outer periphery of the high-elasticity conductive layer has a concave arc-shaped regular hexagonal irregular structure, the side length of which is equal to the cross-sectional diameter of the tin-plated copper single wire on its periphery. The extrusion thickness at the apex of the concave arc ranges from 0.10mm to 0.20mm, and the length of the concave arc is one-quarter of the cross-sectional perimeter of the tin-plated copper single wire, so as to achieve a uniform gap between the single wires when the first layer of conductors is stranded. When the second and third conductors outside the first conductor are stranded, each tinned copper wire is placed in the gap formed by the adjacent tinned copper wires. During stranding, the gaps between the tinned copper wires are filled with 1-3 of high-viscosity, low-hardness conductive sealant, and the excess sealant on the outer surface of the conductor is scraped off to make the conductor look round. This helps to maintain the conductivity of the cable from being affected by the watertight filling.

[0031] Composite insulation: Based on its reliable and flexible bearing capacity under high water pressure, the composite insulation layer adopts a double-layer composite structure, including an inner composite insulation layer and an outer composite insulation layer. The inner composite insulation layer is made of 125℃ low-density polyethylene, and the outer composite insulation layer is made of 150℃ cross-linked polyethylene. During extrusion, the outer layer uses a specially designed serrated die for surface passivation treatment to achieve a rough outer surface of the insulated core, such as... Figure 2 As shown, this improves the cross-bonding and sealing performance between insulation and high-viscosity, low-hardness sealant during unitized cabling.

[0032] Unit-type cabling: Addressing the flexibility requirements of cables in confined spaces, this embodiment designs the cable's bending performance. Using the inner radius r, cabling pitch P, and the distance R between the cable's central axis and the insulated core as parameters, the relative displacement of the conductor core during cable bending is... The stranding and splitting process involves grouping 3-5 watertight stranded conductors with composite insulation into a single unit, setting a pitch ratio of 8-12, and filling the spaces between the conductors with high-viscosity, low-hardness sealant. The surface of the first breathable nonwoven wrapping tape has uniformly distributed perforations, with an overlap rate of 5%-15% and a thickness of 0.03mm-0.07mm. This ensures breathability of the wrapping tape and permeable adhesion of the sealant, facilitating cross-bonding of the sealant between the strands and accelerating sealant curing.

[0033] Each cable unit is then re-stranded into a cable with a pitch ratio of 8-12. A shaped filler core 5 is placed in the center, and a reinforcing filler core 4 is placed in the outer periphery of the cable core of the assembled cable. High-viscosity, low-hardness sealant 6 (performance shown in Table 3) is used for injection between the unit groups. This reduces the outer layer stress when the cable is bent, ensuring bending flexibility. After injection, the cable is placed in an environment with a temperature of 25℃~30℃ and a relative humidity of RH 40%~50% for 10~15 days. During the placement period, the inner and outer layers of the cable are flipped. The reinforcing filler core 4 is a high-strength waterproof elastomer (performance shown in Table 4), with the same appearance as the insulated core, but with a rougher surface. The shaped filler core 5 consists of a central filler core and an outer reinforcing member. The central filler core is used as a spare insulated core for filling, and the outer reinforcing member has a concave arc shape and is made of the same material as the reinforcing filler core 4. The inner circle diameter of the shaped filler core 5 is determined according to the diameter of the surrounding unit wire groups.

[0034] Braided armor and sheath: Tin-plated copper single wires are used for braiding. The diameter, braiding angle, and braiding coverage of the single wires comply with GJB 774A-2020. The braided armor is not wrapped around the outside. During the extrusion of the sheath layer, a tubular hot-injection device is installed between the pay-off reel and the extruder to melt the semi-solid sealant into a colorless and transparent state. The cable is impregnated into the armor single wires through this state of sealant. A soft scraping mold is installed at the sealant outlet to smooth the surface and remove excess sealant, achieving uniform and completely watertight performance in the braided gaps. A cooling system is installed after the injection device to quickly cool the sealant in the armor gaps back to a viscous semi-solid state. Next, a double-layer composite sheath is simultaneously extruded through the extruder using an extrusion process. The inner layer is made of ethylene vinyl acetate, and the extrusion temperature is relatively low, preventing the watertight sealant from undergoing a liquid transformation at the high-temperature die head, resulting in uneven filling. This also enhances adhesion and roundness. The outer layer is made of chlorosulfonated polyethylene or polyether polyurethane compound, and the two layers are tightly bonded through co-extrusion.

[0035] Example 2: A method for manufacturing a 15MPa longitudinal watertight, highly flexible, and heat-resistant cable for cable penetration, comprising the following steps: Step 1: Form a watertight stranded conductor; Step 1.1: Use 19 or 37 tinned copper single wires concentrically twisted together, arranged in a pattern of 1+6+12 and 1+6+12+18 from the center outwards, with a twisting pitch ratio of 8-12 times; Step 1.2: A watertight stranded conductor is formed by tin-plated copper single wires, a high-elasticity conductive layer, and a high-viscosity, low-hardness conductive sealant. The tin-plated copper single wire at the center is surrounded by a high-elasticity conductive layer. The outer periphery of the high-elasticity conductive layer has a concave arc-shaped regular hexagonal irregular structure. The side length is equal to the diameter of the tin-plated copper single wire cross-section. The extrusion thickness at the apex of the concave arc ranges from 0.10mm to 0.20mm. The length of the concave arc is one-quarter of the circumference of the tin-plated copper single wire cross-section, so that a uniform gap appears between the tin-plated copper single wires when the first layer of conductors is stranded. When the second and third conductors outside the first conductor are twisted together, each tinned copper wire is placed in the gap formed by adjacent tinned copper wires inside. When twisting, the gaps between the tinned copper wires are filled with high-viscosity, low-hardness conductive sealant. Step 2: Composite insulation: The composite insulation layer adopts a double-layer composite structure, including an inner composite insulation layer and an outer composite insulation layer. The material used for the inner composite insulation layer is 125℃ low-density polyethylene, and the material used for the outer composite insulation layer is 150℃ cross-linked polyethylene. During extrusion, the outer composite insulation layer is passivated by using a serrated abrasive. Step 3: Unit cabling: 3 to 5 watertight stranded conductors covered with composite insulation layer are stranded together to form a cable unit. The pitch ratio is set to 8 to 12 times. High viscosity and low hardness sealant is filled between the watertight stranded conductors covered with composite insulation layer. The cable unit is wrapped with a first breathable non-woven tape. Step 4: Each sub-cable unit is re-twisted into a cable: Each sub-cable unit wrapped with the first breathable non-woven tape is re-twisted into an assembly cable. A special-shaped filler core is set in the center of the assembly cable, and a reinforcing filler core is set in the gap around the cable core of the assembly cable. High-viscosity, low-hardness sealant is filled between each sub-cable unit, the special-shaped filler core, and the reinforcing filler core. The assembly cable is wrapped with a second breathable non-woven tape. Step 5: Weaving armor: The second breathable non-woven strap is woven with tin-plated copper single wire to form armor, and the gaps in the armor are filled with semi-solid high-temperature resistant sealant. Step 6: The woven armor has an outer sheath layer, which is a double-layer composite sheath.

[0036] The first breathable nonwoven bag has uniformly distributed perforations on its surface, with an overlap rate of 5%-15% and a thickness of 0.03mm-0.07mm.

[0037] The sheath is a double-layer composite sheath, with the inner layer made of ethylene vinyl acetate and the outer layer made of chlorosulfonated polyethylene or polyether polyurethane compound.

[0038] This invention provides a 15MPa longitudinal watertight, highly flexible, and temperature-resistant cable for use in cabins, along with its manufacturing method. Through a special structural watertight stranded conductor design, extruded composite insulation layer, unitized cabling, re-stranding of each cabling unit, combination of breathable non-woven tape and semi-solid high-temperature resistant sealant armor, and sheath layer, the cable possesses the following properties: 15MPa longitudinal watertightness, 0.5MPa longitudinal airtightness, resistance to extreme low temperatures of -54℃, 125℃ compatibility, 95℃ drip resistance, resistance to alternating water pressure (0~15MPa~0), long-term resistance to seawater corrosion, liquid immersion, salt spray, damp heat, and mold resistance; 3D~4D (D is the cable diameter) repeated bending without core breakage; resistance to sunlight radiation; and electrical and watertight performance, vibration, tilt and sway, shock, and cabin reliability after temperature cycling from -54℃ to 90℃.

[0039] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. However, 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 15MPa longitudinal watertight, highly flexible, and temperature-resistant cable for cable passing through a cabin, characterized in that: It includes stranded watertight conductor, composite insulation layer, first breathable nonwoven wrapping tape, reinforcing filler core, irregularly shaped filler core, high-viscosity low-hardness sealant, second breathable nonwoven wrapping tape, braided armor, semi-solid high-temperature resistant sealant, and sheath layer; A composite insulation layer is applied to the outside of a watertight stranded conductor. Several watertight stranded conductors with composite insulation layer are stranded together to form a cable unit. High-viscosity, low-hardness sealant is filled between the watertight stranded conductors with composite insulation layer. The cable unit is wrapped with a first breathable non-woven tape. Each cable unit wrapped with the first breathable nonwoven tape is twisted together to form an assembly cable. A shaped filler core is set in the center of the assembly cable, and a reinforcing filler core is set in the gap around the cable core of the assembly cable. High-viscosity, low-hardness sealant is filled between each cable unit, the shaped filler core, and the reinforcing filler core. The assembly cable is wrapped with a second breathable nonwoven tape. The second breathable non-woven strap is woven with tin-plated copper single wire to form armor, and the gaps in the armor are filled with semi-solid high-temperature resistant sealant. The woven armor has an outer sheath layer, which is a double-layer composite sheath.

2. The 15MPa longitudinal watertight high-flexibility temperature-resistant cable for tunneling as described in claim 1, characterized in that, The watertight stranded conductor uses 19 or 37 tinned copper single wires concentrically stranded, arranged in a pattern of 1+6+12 and 1+6+12+18 from the center outwards, with a stranding pitch ratio of 8-12 times.

3. The 15MPa longitudinal watertight high-flexibility temperature-resistant cable for tunneling as described in claim 2, characterized in that, The watertight stranded conductor consists of tin-plated copper single wires, a highly elastic conductive layer, and a highly viscous, low-hardness conductive sealant. The tin-plated copper single wire at the center is extruded with a high-elasticity conductive layer. The outer periphery of the high-elasticity conductive layer has a concave arc-shaped regular hexagonal irregular structure. The side length is equal to the cross-sectional diameter of the tin-plated copper single wire on its periphery. The extrusion thickness at the apex of the concave arc ranges from 0.10mm to 0.20mm. The length of the concave arc is one-quarter of the cross-sectional perimeter of the tin-plated copper single wire, so that there are uniform gaps between the tin-plated copper single wires when the first layer of conductors is stranded. When the second and third conductors outside the first conductor are stranded, each tinned copper wire is placed in the gap formed by adjacent tinned copper wires inside. During stranding, the gaps between the tinned copper wires are filled with high-viscosity, low-hardness conductive sealant.

4. The 15MPa longitudinal watertight high-flexibility temperature-resistant cable for tunneling as described in claim 1, characterized in that, The composite insulation layer adopts a double-layer composite structure, including an inner composite insulation layer and an outer composite insulation layer. The inner composite insulation layer is made of 125℃ low-density polyethylene, and the outer composite insulation layer is made of 150℃ cross-linked polyethylene. During extrusion, the outer composite insulation layer is passivated by using a serrated abrasive.

5. The 15MPa longitudinal watertight high-flexibility temperature-resistant cable for tunneling as described in claim 1, characterized in that, The number of watertight stranded conductors covered with composite insulation in each cable unit is 3-5, and the section diameter ratio is 8-12 times.

6. The 15MPa longitudinal watertight high-flexibility temperature-resistant cable for tunneling as described in claim 1, characterized in that, The surface of the first breathable nonwoven bag has uniformly distributed perforations, the wrapping overlap rate is 5%-15%, and the thickness is 0.03mm-0.07mm.

7. The 15MPa longitudinal watertight high-flexibility temperature-resistant cable for tunneling as described in claim 1, characterized in that, The sheath is a double-layer composite sheath, with the inner layer made of ethylene vinyl acetate and the outer layer made of chlorosulfonated polyethylene or polyether polyurethane compound.

8. A method for manufacturing a 15MPa longitudinal watertight, highly flexible, and heat-resistant cable for use in cable compartments, characterized in that, Includes the following steps: Step 1: Form a watertight stranded conductor; Step 1.1: Use 19 or 37 tinned copper single wires concentrically twisted together, arranged in a pattern of 1+6+12 and 1+6+12+18 from the center outwards, with a twisting pitch ratio of 8-12 times; Step 1.2: A watertight stranded conductor is formed by tin-plated copper single wires, a high-elasticity conductive layer, and a high-viscosity, low-hardness conductive sealant. The tin-plated copper single wire at the center is surrounded by a high-elasticity conductive layer. The outer periphery of the high-elasticity conductive layer has a concave arc-shaped regular hexagonal irregular structure. The side length is equal to the diameter of the tin-plated copper single wire cross-section. The extrusion thickness at the apex of the concave arc ranges from 0.10mm to 0.20mm. The length of the concave arc is one-quarter of the circumference of the tin-plated copper single wire cross-section, so that a uniform gap appears between the tin-plated copper single wires when the first layer of conductors is stranded. When the second and third conductors outside the first conductor are twisted together, each tinned copper wire is placed in the gap formed by adjacent tinned copper wires inside. When twisting, the gaps between the tinned copper wires are filled with high-viscosity, low-hardness conductive sealant. Step 2: Composite insulation: The composite insulation layer adopts a double-layer composite structure, including an inner composite insulation layer and an outer composite insulation layer. The material used for the inner composite insulation layer is 125℃ low-density polyethylene, and the material used for the outer composite insulation layer is 150℃ cross-linked polyethylene. During extrusion, the outer composite insulation layer is passivated by using a serrated abrasive. Step 3: Unit cabling: 3 to 5 watertight stranded conductors covered with composite insulation layer are stranded together to form a cable unit. The pitch ratio is set to 8 to 12 times. High viscosity and low hardness sealant is filled between the watertight stranded conductors covered with composite insulation layer. The cable unit is wrapped with a first breathable non-woven tape. Step 4: Each sub-cable unit is re-twisted into a cable: Each sub-cable unit wrapped with the first breathable non-woven tape is re-twisted into an assembly cable. A special-shaped filler core is set in the center of the assembly cable, and a reinforcing filler core is set in the gap around the cable core of the assembly cable. High-viscosity, low-hardness sealant is filled between each sub-cable unit, the special-shaped filler core, and the reinforcing filler core. The assembly cable is wrapped with a second breathable non-woven tape. Step 5: Weaving armor: The second breathable non-woven strap is woven with tin-plated copper single wire to form armor, and the gaps in the armor are filled with semi-solid high-temperature resistant sealant. Step 6: The woven armor has an outer sheath layer, which is a double-layer composite sheath.

9. The manufacturing method of the 15MPa longitudinal watertight high-flexibility temperature-resistant cable with a canopy as described in claim 8, characterized in that, The surface of the first breathable nonwoven bag has uniformly distributed perforations, the wrapping overlap rate is 5%-15%, and the thickness is 0.03mm-0.07mm.

10. The high-temperature resistant, high-current-carrying wire for aviation as described in claim 8, characterized in that, The sheath is a double-layer composite sheath, with the inner layer made of ethylene vinyl acetate and the outer layer made of chlorosulfonated polyethylene or polyether polyurethane compound.

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