Integrated forming process of extra-high voltage alternating current and direct current insulation soft sling

Abstract

The invention provides an integrated forming process of an extra-high-voltage alternating-current and direct-current insulating soft sling, belongs to the technical field of high-voltage insulating slings, and solves the technical problems that an existing insulating soft sling is low in preparation efficiency, poor in performance and the like. The integrated forming process of the insulating soft suspender comprises the following steps: weaving a textile fabric layer belt; performing vacuum infiltration; laminating and vulcanizing; performing fiber pretreatment and surface modification; preparing impregnating resin liquid; impregnating the inner and outer coating layers; dipping the modified fiber; integrally forming; heating and curing; carrying out continuous traction and fixed-length cutting; and light-weight end heads are integrally connected. Through multi-layer composite structure innovation and precise material matching, breakthrough improvement of product performance is achieved, the product has the comprehensive protection characteristics of super-hydrophobicity, ultraviolet resistance and the like, and the harsh requirements under the extra-high voltage environment are met; and the production line adopts highly integrated and automatic design, so that the continuity, accuracy and flexibility of production are ensured.

Description

Technical Field

[0001] This invention belongs to the field of high-voltage insulating sling technology, and relates to an integrated molding process for insulating soft slings, particularly an integrated molding process for ultra-high voltage AC / DC insulating soft slings. Background Technology

[0002] In live-line work on ultra-high voltage transmission lines, load-bearing insulated tools are critical safety equipment. Traditional methods often use rigid insulated slings or slings, which suffer from problems such as long length, heavy weight, inconvenient transportation and storage, and poor operational flexibility. In recent years, soft insulated slings made of high-performance fibers such as aramid fiber and impregnated with silicone have emerged, which have solved the drawbacks of rigid tools to some extent.

[0003] However, existing soft insulating sling products still have significant shortcomings: 1. Material and process reliability issues: Some products exhibit surface peeling and bulging, which is related to poor matching of fiber selection, weaving method, impregnation process, and surface treatment technical parameters.

[0004] 2. Weight issue: The material density is relatively high due to the use of aramid fiber and silicone impregnation process. In addition, the ends are mostly made of titanium alloy, resulting in an overall weight that is still relatively heavy, which is not conducive to long-term high-altitude operations.

[0005] 3. Low integration of molding process: The fiber processing, weaving, impregnation, curing, and end connection processes are mostly carried out in separate steps, which is inefficient and makes it difficult to ensure the consistency and reliability of the internal structure. Embedding smart sensors is even more difficult.

[0006] Based on this, we propose an integrated molding process for ultra-high voltage AC / DC insulated soft slings. Summary of the Invention

[0007] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing an integrated molding process for ultra-high voltage AC / DC insulating soft slings. The technical problem this invention aims to solve is: how to efficiently and stably produce high-strength, high-performance insulating soft slings through an integrated molding process, while meeting the requirements of ultra-high voltage AC / DC power grids.

[0008] The objective of this invention can be achieved through the following technical solutions: An integrated molding process for ultra-high voltage AC / DC insulating flexible slings includes the following steps: Step 1, weaving textile layers: Weaving fibers to obtain fiber fabric layers; Step 2, Vacuum Impregnation: The fiber fabric layer is immersed in insulating liquid silicone under vacuum. The liquid silicone penetrates into the fiber fabric layer. After half an hour, it is taken out and dried to obtain a dried layer. Step 3, Layered vulcanization: Several dried layers are stacked together and placed inside the vulcanization equipment for vulcanization. After vulcanization, silicone interlayers are formed between the dried layers, and a silicone protective layer is formed on the outer surface after vulcanization, thus obtaining the vulcanized belt core material. Step 4, fiber pretreatment and surface modification: Select at least one of high-strength polyethylene fiber and poly(p-phenylenebenzobisoxazole) fiber as reinforcing fiber, and perform surface modification treatment on the fiber to improve its interfacial bonding force with the resin matrix; dry the modified fiber at a set temperature and roll it up for later use. Step 5, preparing the impregnation resin solution: The impregnation resin solution comprises: a matrix resin: a low-viscosity, high-insulation epoxy resin system or a special unsaturated polyester resin; a curing agent: 4,4'-diaminodiphenyl sulfone or a corresponding anhydride curing agent, added at a mass ratio of resin to curing agent of 100:25 to 100:35; a moisture-proof reinforcing component: hydrophobic fillers, including but not limited to nano-silica and fumed silica, accounting for 3%-8%; and functional additives: including but not limited to ultraviolet absorbers and antioxidants. Step 6, Impregnating the inner and outer coating layers: Using TPU film rolls of two different widths as the main body of the inner and outer coating layers, respectively, they are immersed into the impregnation resin liquid at the corresponding positions to obtain the inner impregnation layer and the outer impregnation layer. Step 7, Impregnating modified fibers: The modified fibers are rolled up and immersed in the impregnation resin solution at the corresponding positions to form impregnated fibers; Step 8, Integrated molding: Inner layer coating: The vulcanized belt core material from step 3 is coated from the top and bottom and left and right sides of the vulcanized belt core material with two widths respectively through the inner impregnation layer from step 6 to obtain the first coating layer; Fiber coating: Several impregnated fibers from step seven are coated from the top and bottom and left and right sides of the first coating layer to obtain a fiber coating layer; Outer coating: The fiber coating layer is coated from the top and bottom and left and right sides of the fiber coating layer with two widths respectively through the outer impregnation layer in step six to obtain the second coating layer; Step 9, Heating and Curing: The belt with the second coating layer is introduced into the heating and curing mold. The temperature of the heating and curing mold is controlled in zones. Under the action of the traction mechanism, the belt is compressed and heated in the mold to complete the gelation and curing of the resin. Step 10, Continuous traction and fixed-length cutting: The cured and coated continuous sling is pulled out at a constant speed by the traction mechanism; Step 11, Lightweight Integrated End Connection: A lightweight metal alloy end connector with topology optimization design is adopted; after pre-processing the cut end of the sling obtained in Step 10, it is inserted into the slot of the end connector, and high-strength epoxy resin structural adhesive is injected into the slot. After curing, a high-strength, integrated connection between the sling and the end is achieved by "adhesive riveting composite".

[0009] In step one, the fiber used is at least one of carbon fiber and modified aramid fiber, or a mixture of them in a specific ratio of 3:7 to 5:5, to balance strength, modulus, insulation and cost; the thickness of the fiber fabric layer in step one is 0.5±0.05 mm.

[0010] In step three, the thickness of the silicone interlayer is 0.3±0.05 mm, and the thickness of the silicone protective layer is 0.5±0.05 mm.

[0011] The modification methods in step four include dopamine biomimetic modification or plasma treatment. Dopamine biomimetic modification involves immersing the fiber in a dopamine / Tris hydrochloride buffer solution with pH=8.5 and stirring at 30°C for 2-5 hours to uniformly coat the fiber surface with a polydopamine film, increasing surface roughness and reactive sites. Plasma treatment involves using oxygen or ammonia plasma to treat the fiber for a short time, introducing oxygen- or nitrogen-containing polar functional groups.

[0012] In step nine, the temperature of the mold is 80-100°C in the inlet zone, 130-160°C in the middle zone, and 160-180°C in the outlet zone.

[0013] The equipment used in steps five to ten includes a skid-mounted base, and the upper end of the skid-mounted base is provided with an impregnation molding mechanism, a fiber impregnation mechanism, a fiber forming mechanism, an impregnation molding mechanism, a heating and curing mold, a traction mechanism, and a cutting mechanism in sequence from front to back.

[0014] Using the above structure, the prepared impregnation resin solution is placed inside two impregnation molding mechanisms and a fiber impregnation mechanism. Two widths of TPU film rolls are placed on the two impregnation molding mechanisms for resin impregnation, resulting in an inner impregnation layer and an outer impregnation layer, respectively. Modified fiber rolls are placed on the fiber impregnation mechanism for resin impregnation, resulting in impregnated fibers. The vulcanized belt core material is sequentially passed through the impregnation molding mechanism, fiber impregnation mechanism, fiber forming mechanism, impregnation molding mechanism again, heat curing mold, traction mechanism, and cutting mechanism. The traction mechanism provides continuous and stable traction force to transport the vulcanized belt core material. When the vulcanized belt core material passes through the front impregnation molding mechanism, the front impregnation molding mechanism covers the vulcanized belt core material with two widths of inner impregnation layers from the top and bottom and left and right sides, respectively, to obtain the first covering layer. When the vulcanized belt core material passes through the fiber forming mechanism, several strands of… The impregnated fibers are coated from the top and bottom, and left and right sides of the first coating layer by a fiber forming mechanism to obtain a fiber coating layer. When the vulcanized belt core material passes through the rear impregnation forming mechanism, the rear impregnation forming mechanism coats the fiber coating layer from the top and bottom, and left and right sides of the fiber coating layer with two different widths to obtain a second coating layer. When the vulcanized belt core material passes through the heating and curing mold, the belt bundle coated with the second coating layer is introduced into the heating and curing mold. The temperature of the heating and curing mold is controlled in zones. Under the action of the traction mechanism, the belt bundle is pressed and heated in the mold to complete the gelation and curing of the resin, firmly bonding the fiber, film and vulcanized belt core material into a whole. The vulcanized belt core material is pulled out by the traction mechanism and transported to the cutting mechanism. After cooling, the cutting mechanism cuts it to a set length. The whole process is continuous, closed and automated, ensuring the consistency of product performance and production efficiency.

[0015] The impregnation molding mechanism includes an impregnation frame and an impregnation tank. Both the frame and tank are fixed to the upper end of a skid-mounted base. The impregnation tank is located inside the frame. The rear side of the frame has two symmetrically arranged hollow side rollers and two symmetrically arranged hollow pressure rollers, forming a feeding chamber between them. The front side of the frame has two symmetrically arranged side roll rollers and two symmetrically arranged face roll rollers. Side roll films are detachably mounted on the side roll rollers, and face roll films are detachably mounted on the face roll rollers. Impregnation rollers are rotatably mounted inside the impregnation tank. The upper end has symmetrically arranged guide components on both the front and rear sides. The first tensioning frame is located on the dip-in roll and the rear guide component. The guide component includes a side guide frame, which is fixed to the upper end of the dip-in roll. The inner side of the side guide frame has two left-right symmetrical side guide rollers and two up-down symmetrical transverse guide rollers. The inner middle of the side guide frame has two left-right symmetrical variable angle seats, and the variable angle seats are rotatably equipped with variable angle rollers inside. The lower inner part of the side guide frame has two left-right symmetrical lower guide seats, and the lower guide seats are rotatably equipped with lower guide rollers inside.

[0016] Using the above structure, the prepared impregnation resin solution is placed inside the impregnation tank. The face roll is a TPU film roll with a width matching the core material of the vulcanized belt, and the side roll is a TPU film roll with a thickness matching the core material of the vulcanized belt. The face roll and side roll are installed onto the face roll roller and side roll roller at the corresponding positions, and released from the face roll roller and side roll roller under the action of traction force. The face roll passes sequentially through the transverse guide rollers of the front guide assembly, the impregnation roller, the first tensioning frame, and the transverse guide rollers of the rear guide assembly to complete the resin impregnation. Finally, it passes through two hollow pressure rollers and is pressed into the vulcanized belt core material. The side-wound film passes sequentially through the side guide rollers, variable angle rollers, and lower guide rollers of the front guide assembly, then through the layer impregnation roller and the first tensioning frame, and then sequentially through the lower guide rollers, variable angle rollers, and side guide rollers of the rear guide assembly to complete resin impregnation. Finally, it passes through two hollow side rollers and is pressed firmly onto the left and right ends of the vulcanized core material or fiber-coated layer. The variable angle roller performs precise path planning for the side TPU film roll, and places the side TPU film roll horizontally between the two guide assemblies to ensure stable resin impregnation.

[0017] The fiber impregnation mechanism includes an impregnation frame and an impregnation assembly. The impregnation frame is fixed to the upper end of the skid-mounted base, and the impregnation assembly is set at the upper end of the skid-mounted base. The front side of the impregnation frame is provided with two sets of left-right symmetrical fiber side rolls and two sets of top-bottom symmetrical fiber surface rolls. The rear side of the impregnation frame is provided with two left-right symmetrical hollow side fiber guide rollers and two sets of top-bottom symmetrical hollow surface fiber guide rollers. The impregnation assembly includes an impregnation box, inside which the impregnation rollers are rotatably mounted. The upper end of the impregnation box is provided with two sets of symmetrically arranged dividing rods on the front and rear sides. The impregnation box is provided with a second tensioning frame, which is located between the impregnation rollers and the set of dividing rods on the rear side.

[0018] Using the above structure, the prepared impregnation resin solution is placed inside the fiber impregnation tank. The fiber side rolls and fiber face rolls are modified fiber rolls, which are released under traction force. The modified fiber bundles drawn from the fiber side rolls and fiber face rolls are guided by several separating uprights on the front side and pass around the fiber impregnation roller, ensuring that each modified fiber bundle is fully and evenly impregnated by the resin solution, so that the resin coats each monofilament. The separating uprights physically separate the fiber bundles from different fiber rolls that are heading in different directions (top, bottom, left, right), preventing them from contacting, entangled, rubbing, or sticking together before and after impregnation, ensuring that each fiber bundle is completed independently and flat. Impregnation and maintaining a neat arrangement are crucial for the uniformity of the final product's mechanical properties. A second tensioner provides adjustable fiber tension, preventing the soft, impregnated fiber bundles from loosening, sagging, or sticking together by applying appropriate, stable tension, ensuring they enter the subsequent guide roller system in a taut, neat state. Hollow-side fiber guide rollers guide the resin-impregnated fiber bundles for the upper and lower surfaces, accurately positioning them on the upper and lower sides of the incoming core material. Hollow-side fiber guide rollers guide the resin-impregnated fiber bundles for the left and right sides, accurately positioning them on the left and right sides of the incoming core material.

[0019] The fiber forming mechanism includes a fiber forming mold, which is set on the upper end of the skid-mounted base. The fiber forming mold has a main channel inside, which is wedge-shaped with a larger front and a smaller rear. The inner side of the fiber forming mold has two sets of vertically symmetrical surface guide channels and two sets of horizontally symmetrical side guide channels. The surface guide channels and side guide channels penetrate the fiber forming mold. The front ends of the two sets of surface guide channels are respectively aligned with the hollow surface fiber guide rollers, and the front ends of the two sets of side guide channels are respectively aligned with the hollow side fiber guide rollers. The end of the fiber forming mold has a pressing port, and the ends of the side guide channels and surface guide channels are located at the pressing port. The left and right sides of the fiber forming mold have two sets of symmetrically arranged air inlets, which are connected to the main channel.

[0020] Using the above structure, the following steps are employed: Alignment and Introduction: The four sets of fiber bundles output from the fiber impregnation mechanism are precisely introduced into the corresponding face guide channels and side guide channels of the fiber forming mold; Core Material Positioning: The core material, wrapped with the first coating layer, enters from the wide end of the main channel; Gradual Convergence: Under the pull of traction, the core material and the four fiber bundles move forward in the main channel and their respective guide channels; The wedge-shaped main channel and the gradually narrowing guide channels gradually compress and organize them, bringing their shape closer to the final size; Integrated Pressing: All components converge at the pressing port and are tightly pressed together to form a pre-formed fiber coating layer; Auxiliary Protection: Clean heated airflow provided by the air inlet duct ensures the stability of the mold environment throughout the process, preventing premature curing and contamination; Output: The formed fiber coating layer is output from the pressing port and enters the next stage of the production line.

[0021] The heat-curing mold includes a traction frame, which is set on the upper end of the skid-mounted base. A heater and an induced draft fan are provided on the lower side of the traction frame. An electric conveyor belt is provided on the traction frame. An oven is provided in the middle of the traction frame. Both the traction frame and the electric conveyor belt pass through the oven. The air inlet of the induced draft fan is connected to the air outlet of the heater. The air outlet of the induced draft fan is connected to the lower end of the oven. Two molding models are fixed on the upper end of the traction frame and are arranged symmetrically front and back. The two molding models are respectively connected to the front and rear sides of the oven. A filter exhaust box is provided on the upper end of the oven and is connected to it. An exhaust fan is provided on the upper end of the oven. The air inlet of the exhaust fan is connected to the air outlet of the filter exhaust box. The air outlet of the exhaust fan is connected to the hollow pressure roller, the hollow side roller, the hollow fiber guide roller, the hollow side fiber guide roller, and the air inlet pipe through pipes.

[0022] Using the above structure, the heater generates a heat source, and the induced draft fan forcefully blows the heated air into the oven. The temperature inside the oven is controlled as follows: 80-100℃ in the inlet zone, 130-160℃ in the middle curing zone, and 160-180℃ in the outlet zone. Initial shaping: The coated belt first passes through the forming mold at the front end, where its shape is initially shaped. Zone curing: Under the support and traction of the electric conveyor belt and traction mechanism, the belt passes through the oven at a uniform speed. Under precise zone temperature control, the resin undergoes gelation and complete curing. Waste gas and heat recovery: The hot air generated during the curing process is drawn out by an exhaust fan, purified by a filter exhaust box, and then discharged by the exhaust fan. The purified medium-low temperature hot air is redistributed through pipes to the preceding impregnation and molding stations, including hollow pressure rollers, hollow side rollers, hollow fiber guide rollers, hollow side fiber guide rollers, and air inlet pipes. The gentle hot air passing through these rollers and pipes serves two important purposes: preliminary resin curing and pre-gelling: ensuring rapid preliminary curing of the resin-impregnated film and fibers before entering the main curing oven to prevent resin dripping; preheating and drying: preheating the materials and semi-finished products to reduce thermal shock upon entering the oven and to help remove any remaining trace amounts of moisture or solvent; and secondary shaping: the fully cured slings undergo final shaping via the rear molding mold.

[0023] The traction mechanism includes a traction base frame, on which are provided several horizontally arranged adjusting slide shafts. Two symmetrically arranged slide frames slide on the adjusting slide shafts. Two symmetrically arranged adjusting electric screws are fixed to the upper end of the traction base frame. The slide frames are fixedly connected to the sliding seats of the adjusting electric screws on the same side. Two pull wheels are rotatably provided at the upper end of each slide frame. A traction track is provided between the two pull wheels. The lower circumference of the traction track is provided with a material placement protrusion. A traction motor is fixed to the lower end of each slide frame. The output shaft of the traction motor is fixedly connected to one of the traction wheels on the same side.

[0024] With the above structure, the control system sends commands to the two adjusting electric screws, which rotate precisely, pushing or pulling the two sliding frames to move synchronously in opposite directions along the adjusting slide shaft. The movement of the sliding frames causes the entire traction track on them to move together, thereby precisely adjusting the clamping distance between the two traction tracks to adapt to sling products of different widths. The traction motor starts, drives the traction wheel, and drives the traction track to rotate. The traction track clamps the sling, and the material placement protrusions on its surface support the sling, achieving constant speed traction of the sling.

[0025] The cutting mechanism includes a cutter holder, an inverted U-shaped cutter frame at the upper end of the cutter holder, a downward-extending electric push rod fixed in the middle of the cutter frame, a cutter fixed below the extension end of the electric push rod, and two symmetrical vertical sliding shafts fixed at the upper end of the cutter, which are slidably mounted on the cutter frame.

[0026] With the above structure, in standby mode: during normal traction, the lifting electric push rod is in the retracted state, and the cutter is raised to its highest point, clearing the way for the sling, allowing production to continue continuously; trigger signal: when the length of the sling delivered by the traction mechanism reaches the preset value, the measuring sensor sends a signal to the control system; execute cutting: the control system immediately commands the lifting electric push rod to extend instantaneously, pushing the cutter to move vertically downward at high speed along the guide of the vertical sliding shaft, cutting the sling; quick reset: after cutting is completed, the lifting electric push rod retracts instantaneously, driving the cutter to quickly rise and leave the cutting area, restoring the passage and waiting for the next cutting command.

[0027] Compared with existing technologies, the integrated molding process of this ultra-high voltage AC / DC insulated flexible sling has the following advantages: This process achieves a breakthrough in product performance through innovative multi-layer composite structure and precise material formulation; it ensures that the product has comprehensive protective properties such as superhydrophobicity and UV resistance, meeting the stringent requirements of ultra-high voltage environments.

[0028] The production line adopts a highly integrated and automated design, ensuring the continuity, accuracy, and flexibility of production.

[0029] This technology system achieves an organic unity of quality, efficiency, and environmental protection. Automated production improves product qualification rate, enhances performance consistency, and increases production efficiency compared to traditional processes. Closed-loop production and heat energy recycling reduce energy consumption and VOC emissions, combining economic benefits with environmental friendliness, and providing reliable technical support for the manufacturing of ultra-high voltage equipment. Attached Figure Description

[0030] Figure 1 This is a flowchart of the process flow of the present invention.

[0031] Figure 2 This is a schematic diagram of the structure of some of the devices in this invention.

[0032] Figure 3 This is a three-dimensional structural diagram of the impregnation molding mechanism in this invention.

[0033] Figure 4 This is a schematic diagram of some components of the impregnation molding mechanism in this invention.

[0034] Figure 5 This is a three-dimensional structural diagram of the fiber impregnation mechanism in this invention.

[0035] Figure 6 This is a schematic diagram of some components of the fiber impregnation mechanism in this invention.

[0036] Figure 7 This is a schematic diagram of the fiber forming mechanism in this invention.

[0037] Figure 8 This is a schematic diagram of the structure of the heat curing mold in this invention.

[0038] Figure 9 This is a schematic diagram of the traction mechanism in this invention.

[0039] Figure 10 This is a schematic diagram of the cutting mechanism in this invention.

[0040] In the diagram: 1. Skid-mounted base; 2. Impregnation and forming mechanism; 3. Fiber impregnation mechanism; 4. Fiber forming mechanism; 5. Heating and curing mold; 6. Traction mechanism; 7. Cutting mechanism; 8. Impregnation frame; 9. Hollow pressure roller; 10. Hollow side roller; 11. Guide assembly; 12. Side roll roller; 13. Face roll roller; 14. Face roll film; 15. Side roll film; 16. Impregnation roller; 17. Impregnation box; 18. First tension frame; 19. Side guide frame; 20. Horizontal guide double roller; 21. Side guide double roller; 22. Angle seat; 23. Angle double roller; 24. Lower guide double roller; 25. Lower guide seat; 26. Fiber impregnation frame; 27. Fiber impregnation assembly; 28. Fiber side roll; 29. ​​Fiber face roll; 30. Hollow face fiber. 31. Hollow side fiber guide roller; 32. Fiber impregnation box; 33. Second tensioning frame; 34. Separating upright; 35. Fiber impregnation roller; 36. Side guide channel; 37. Air inlet pipe; 38. Main channel; 39. Surface guide channel; 40. Pressing port; 41. Fiber forming mold; 42. Heater; 43. Traction frame; 44. Electric conveyor belt; 45. Forming mold; 46. Filter exhaust box; 47. Exhaust fan; 48. Traction wheel; 49. Traction belt; 50. Material placement protrusion; 51. Traction base frame; 52. Sliding frame; 53. Adjusting electric lead screw; 54. Adjusting slide shaft; 55. Lifting electric push rod; 56. Cutter; 57. Cutter holder; 58. Cutter seat; 59. Vertical slide shaft. Detailed Implementation

[0041] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0042] like Figures 1-10 As shown, the integrated molding process of this ultra-high voltage AC / DC insulated flexible sling includes the following steps: Step 1, weaving textile layers: Weaving fibers to obtain fiber fabric layers; Step 2, Vacuum Impregnation: The fiber fabric layer is immersed in insulating liquid silicone under vacuum. The liquid silicone penetrates into the fiber fabric layer. After half an hour, it is taken out and dried to obtain a dried layer. Step 3, Layered vulcanization: Several dried layers are stacked together and placed inside the vulcanization equipment for vulcanization. After vulcanization, silicone interlayers are formed between the dried layers, and a silicone protective layer is formed on the outer surface after vulcanization, thus obtaining the vulcanized belt core material. Step 4, fiber pretreatment and surface modification: Select at least one of high-strength polyethylene fiber and poly(p-phenylenebenzobisoxazole) fiber as reinforcing fiber, and perform surface modification treatment on the fiber to improve its interfacial bonding force with the resin matrix; dry the modified fiber at a set temperature and roll it up for later use. Step 5, Prepare the impregnation resin solution: The impregnation resin solution comprises: Matrix resin: Low viscosity, high insulation performance epoxy resin system (such as E-51 type) or special unsaturated polyester resin; Curing agent: DDS (4,4'-diaminodiphenyl sulfone) or corresponding anhydride curing agent, added at a mass ratio of resin to curing agent of 100:25 to 100:35; Moisture-proof reinforcement components: including but not limited to nano-silica and fumed silica hydrophobic fillers, accounting for 3%-8%; Functional additives: including but not limited to ultraviolet absorbers and antioxidants; Step 6, Impregnating the inner and outer coating layers: Using TPU film rolls of two different widths as the main body of the inner and outer coating layers, respectively, they are immersed into the impregnation resin liquid at the corresponding positions to obtain the inner impregnation layer and the outer impregnation layer. Step 7, Impregnating modified fibers: The modified fibers are rolled up and immersed in the impregnation resin solution at the corresponding positions to form impregnated fibers; Step 8, Integrated Molding: Inner coating: The vulcanized belt core material from step three is coated from the top and bottom and left and right sides of the vulcanized belt core material with two widths respectively through the inner impregnation layer from step six to obtain the first coating layer; Fiber coating: Several impregnated fibers from step seven are coated from the top and bottom and left and right sides of the first coating layer to obtain a fiber coating layer; Outer coating: The fiber coating layer is coated from the top and bottom and left and right sides of the fiber coating layer with two widths respectively through the outer impregnation layer in step six to obtain the second coating layer; Step 9, Heating and Curing: The belt with the second coating layer is introduced into the heating and curing mold. The temperature of the heating and curing mold is controlled in zones. Under the action of the traction mechanism, the belt is compressed and heated in the mold to complete the gelation and curing of the resin. Step 10, Continuous traction and fixed-length cutting: The cured and coated continuous sling is pulled out at a constant speed by the traction mechanism; Step 11, Lightweight Integrated End Connection: A lightweight metal alloy (such as titanium alloy or titanium fiber metal alloy) end connector with topology optimization design is used. The cut end of the sling obtained in Step 10 is pre-treated (pre-treatment includes: removing 20-30mm of the outer covering layer at the end, sanding the core material surface with 120-grit sandpaper, and wiping with acetone to remove oil). After that, it is inserted into the slot of the end connector, and high-strength epoxy resin structural adhesive is injected into the slot. After curing, a high-strength, integrated connection between the sling and the end is achieved by "adhesive riveting composite".

[0043] In step one, the fiber used is at least one of carbon fiber and modified aramid fiber, or a mixture in a specific ratio such as 3:7 to 5:5, to balance strength, modulus, insulation and cost; the thickness of the fiber fabric layer in step one is 0.5±0.05 mm.

[0044] In step three, the thickness of the silicone interlayer is 0.3±0.05 mm, and the thickness of the silicone protective layer is 0.5±0.05 mm.

[0045] The modification methods in step four include dopamine biomimetic modification or plasma treatment. Dopamine biomimetic modification involves immersing the fiber in a dopamine / Tris hydrochloride buffer solution at pH 8.5 and stirring at 30°C for 2-5 hours to uniformly coat the fiber surface with a polydopamine film, increasing surface roughness and reactive sites. Plasma treatment involves using oxygen or ammonia plasma to treat the fiber for a short time, introducing oxygen- or nitrogen-containing polar functional groups.

[0046] In step nine, the temperature of the mold's inlet zone is 80-100℃, the middle curing zone is 130-160℃, and the outlet zone is 160-180℃.

[0047] The equipment used in steps five to ten includes a skid-mounted base 1. The upper end of the skid-mounted base 1 is provided with, from front to back, an impregnation molding mechanism 2, a fiber impregnation mechanism 3, a fiber forming mechanism 4, an impregnation molding mechanism 2, a heating and curing mold 5, a traction mechanism 6, and a cutting mechanism 7.

[0048] The prepared impregnation resin solution is placed inside two impregnation molding mechanisms 2 and a fiber impregnation mechanism 3. Two widths of TPU film rolls are placed on the two impregnation molding mechanisms 2 for resin impregnation, resulting in an inner impregnation layer and an outer impregnation layer. Modified fiber rolls are placed on the fiber impregnation mechanism 3 for resin impregnation, resulting in impregnated fibers. The vulcanized belt core material is sequentially passed through impregnation molding mechanism 2, fiber impregnation mechanism 3, fiber forming mechanism 4, impregnation molding mechanism 2, a heat curing mold 5, a traction mechanism 6, and a cutting mechanism 7. The traction mechanism 6 provides continuous and stable traction force to transport the vulcanized belt core material. When the vulcanized belt core material passes through the front impregnation molding mechanism 2, the front impregnation molding mechanism 2 covers the vulcanized belt core material with two widths of inner impregnation layers from the top and bottom and left and right sides, respectively, to obtain the first covering layer. When the vulcanized belt core material passes through the fiber forming mechanism 4, several strands of… The impregnated fibers are coated from the top and bottom and left and right sides of the first coating layer by the fiber forming mechanism 4 to obtain the fiber coating layer. When the vulcanized belt core material passes through the rear impregnation forming mechanism 2, the rear impregnation forming mechanism 2 coats the fiber coating layer from the top and bottom and left and right sides with two different widths of inner impregnation layers to obtain the second coating layer. When the vulcanized belt core material passes through the heating and curing mold 5, the belt bundle coated with the second coating layer is introduced into the heating and curing mold 5. The temperature of the heating and curing mold 5 is controlled in zones. Under the action of the traction mechanism, the belt bundle is pressed and heated in the mold to complete the gelation and curing of the resin, and firmly combines the fiber, film and vulcanized belt core material into a whole. The vulcanized belt core material is pulled out by the traction mechanism 6 and transported to the cutting mechanism 7. After cooling, the cutting mechanism 7 cuts it to the set length. The whole process is continuous, closed and automated, ensuring the consistency of product performance and production efficiency.

[0049] The immersion molding mechanism 2 includes an immersion frame 8 and an immersion tank 17. Both the immersion frame 8 and the immersion tank 17 are fixed to the upper end of the skid-mounted base 1. The immersion tank 17 is located inside the immersion frame 8. The rear side of the immersion frame 8 is provided with two symmetrical hollow side rollers 10 and two symmetrical hollow pressure rollers 9. A feeding pressure cavity is formed between the two hollow side rollers 10 and the two hollow pressure rollers 9. The front side of the immersion frame 8 is provided with two symmetrical side roll rollers 12 and two symmetrical face roll rollers 13. Side roll films 15 are detachably mounted on the side roll rollers 12, and face roll films 14 are detachably mounted on the face roll rollers 13. Immersion rollers 16 are rotatably mounted inside the immersion tank 17. The upper end of the immersion tank 17 is front and rear. The guide assembly 11 is symmetrically arranged on both sides. The first tension frame 18 is provided on the impregnation tank 17. The first tension frame 18 is located between the impregnation roller 16 and the rear guide assembly 11. The guide assembly 11 includes a side guide frame 19. The side guide frame 19 is fixed to the upper end of the impregnation tank 17. The inner side of the side guide frame 19 is provided with two left-right symmetrical side guide double rollers 21 and two up-down symmetrical transverse guide double rollers 20. The inner middle of the side guide frame 19 is provided with two left-right symmetrical variable angle seats 22. The variable angle seats 22 are rotatably provided with variable angle double rollers 23 inside each of them. The lower inner part of the side guide frame 19 is fixed with two left-right symmetrical lower guide seats 25. The lower guide seats 25 are rotatably provided with lower guide double rollers 24 inside each of them.

[0050] The prepared impregnation resin solution is placed inside the impregnation tank 17. The face roll 14 is a TPU film roll matching the width of the vulcanized belt core material, and the side roll 15 is a TPU film roll matching the thickness of the vulcanized belt core material. The face roll 14 and the side roll 15 are installed onto the face roll roller 13 and the side roll roller 12 at the corresponding positions, and released from the face roll roller 13 and the side roll roller 12 under the action of traction force. The face roll 14 passes sequentially through the transverse guide double roller 20 of the front guide assembly 11, the impregnation roller 16, the first tension frame 18, and the transverse guide double roller 20 of the rear guide assembly 11 to complete the resin impregnation. Finally, it passes through two hollow pressure rollers 9 and is pressed into the vulcanized belt core material or The upper and lower end faces of the fiber coating layer; the side roll film 15 passes sequentially through the side guide double roller 21, the variable angle double roller 23 and the lower guide double roller 24 of the front guide assembly 11, then through the layer impregnation roller 16 and the first tensioning frame 18, and then sequentially through the lower guide double roller 24, the variable angle double roller 23 and the side guide double roller 21 of the rear guide assembly 11 to complete the resin impregnation, and finally passes through the two hollow side rollers 10 to be pressed into the left and right end faces of the vulcanized belt core material or the fiber coating layer; the variable angle double roller 23 performs precise path planning for the side TPU film roll, and places the side TPU film roll horizontally between the two guide assemblies 11 to ensure stable resin impregnation.

[0051] The fiber impregnation mechanism 3 includes an impregnation frame 26 and an impregnation assembly 27. The impregnation frame 26 is fixed to the upper end of the skid-mounted base 1, and the impregnation assembly 27 is set at the upper end of the skid-mounted base 1. The front side of the impregnation frame 26 is provided with two sets of left-right symmetrical fiber side rolls 28 and two sets of top-bottom symmetrical fiber surface rolls 29. The rear side of the impregnation frame 26 is provided with two left-right symmetrical hollow side fiber guide rollers 31 and two sets of top-bottom symmetrical hollow surface fiber guide rollers 30. The impregnation assembly 27 includes an impregnation box 32. The impregnation roller 35 is rotatably installed inside the impregnation box 32. The front and rear sides of the upper end of the impregnation box 32 are provided with two sets of symmetrically arranged dividing rods 34. The impregnation box 32 is provided with a second tensioning frame 33, which is located between the impregnation roller 35 and the set of dividing rods 34 on the rear side.

[0052] The prepared impregnation resin solution is placed inside the fiber impregnation tank 32. Fiber side rolls 28 and fiber face rolls 29, which are modified fiber rolls, are released under traction. The modified fiber bundles drawn from the fiber side rolls 28 and fiber face rolls 29, guided by several separating rods 34 on the front side, pass around the fiber impregnation roller 35, ensuring that each modified fiber bundle is fully and evenly impregnated by the resin solution, allowing the resin to coat each monofilament. The separating rods 34 physically separate fiber bundles from different fiber rolls that are heading in different directions (top, bottom, left, right), preventing them from contacting, entangled, rubbing, or sticking together before and after impregnation, ensuring that each fiber bundle can be independently and flatly impregnated. Complete impregnation and maintain a neat arrangement, which is crucial for the uniformity of the mechanical properties of the final product; the second tensioner 33 provides adjustable fiber tension, preventing the soft fiber bundles after impregnation from loosening, sagging, or sticking together by applying appropriate and stable tension, ensuring that they can enter the subsequent guide roller system in a taut and neat state; hollow fiber guide roller 30: guides the resin-impregnated fiber bundles for the upper and lower surfaces, accurately positioning them on the upper and lower sides of the incoming core material; hollow fiber guide roller 31: guides the resin-impregnated fiber bundles for the left and right sides, accurately positioning them on the left and right sides of the incoming core material.

[0053] The fiber forming mechanism 4 includes a fiber forming mold 41, which is set at the upper end of the skid-mounted base 1. The fiber forming mold 41 has a main channel 38 inside, which is wedge-shaped with a larger front and a smaller rear. The inner side of the fiber forming mold 41 has two sets of vertically symmetrical surface guide channels 39 and two sets of horizontally symmetrical side guide channels 36. The surface guide channels 39 and the side guide channels 36 penetrate the fiber forming mold 41. The front ends of the two sets of surface guide channels 39 are respectively aligned with the hollow surface fiber guide rollers 30, and the front ends of the two sets of side guide channels 36 are respectively aligned with the hollow side fiber guide rollers 31. The end of the fiber forming mold 41 has a pressing port 40, and the ends of the side guide channels 36 and the surface guide channels 39 are located at the pressing port 40. The left and right sides of the fiber forming mold 41 have two sets of symmetrically arranged air inlet pipes 37, which are connected to the main channel 38.

[0054] Alignment and Import: The four sets of fiber bundles output from the fiber impregnation mechanism 3 are precisely imported into the corresponding face guide channel 39 and side guide channel 36 of the fiber forming mold 41; Core Material Positioning: The core material wrapped with the first coating layer enters from the wide end of the main channel 38; Gradual Convergence: Under the pull of the traction force, the core material and the four fiber bundles move forward in the main channel and their respective guide channels; The wedge-shaped main channel and the gradually narrowing guide channels gradually compress and organize them, and the shape tends to the final size; Integrated Pressing: All components converge at the pressure port 40 and are tightly pressed together to form a pre-formed fiber coating layer; Auxiliary Protection: The clean heated airflow provided by the air inlet pipe 37 ensures the stability of the mold environment throughout the process, preventing premature curing and contamination; Output: The formed fiber coating layer is output from the pressure port 40 and enters the next stage of the production line (i.e., the impregnation forming mechanism 2 on the rear side, for the outer TPU film coating).

[0055] The heat-curing mold 5 includes a traction frame 43, which is located on the upper end of the skid-mounted base 1. A heater 42 and an induced draft fan 47 are located on the lower side of the traction frame 43. An electric conveyor belt 44 is mounted on the traction frame 43. An oven is located in the middle of the traction frame 43, and both the traction frame 43 and the electric conveyor belt 44 pass through the oven. The air inlet of the induced draft fan 47 is connected to the air outlet of the heater 42, and the air outlet of the induced draft fan 47 is connected to the lower end of the oven. Two symmetrically arranged molding models 45 are fixed at the upper end of the frame 43. The two molding models 45 are respectively connected to the front and rear sides of the oven. A filter exhaust box 46 is provided at the upper end of the oven and is connected to it. An exhaust fan is provided at the upper end of the oven. The air inlet of the exhaust fan is connected to the air outlet of the filter exhaust box 46. The air outlet of the exhaust fan is connected to the hollow pressure roller 9, the hollow side roller 10, the hollow surface fiber guide roller 30, the hollow side fiber guide roller 31 and the air inlet pipe 37 through pipes.

[0056] Heater 42 generates a heat source, and blower 47 forcefully blows the heated air into the oven. The temperature inside the oven is controlled as follows: 80-100℃ in the inlet zone, 130-160℃ in the middle curing zone, and 160-180℃ in the outlet zone. Preliminary shaping: The coated belt first passes through the forming mold 45 at the front end, where its shape is initially shaped. Zoned curing: The belt passes through the oven at a uniform speed under the support of the electric conveyor belt 44 and the traction mechanism 6. Under precise zoned temperature control, the resin undergoes gelation and complete curing. Waste gas and heat recovery: The hot air generated during the curing process is drawn out by the exhaust fan, purified by the filter exhaust box 46, and then discharged by the exhaust fan. The medium-low temperature hot air is redistributed through pipes to the preceding impregnation and molding station, including hollow pressure rollers 9, hollow side rollers 10, hollow fiber guide rollers 30, hollow side fiber guide rollers 31, and air inlet pipes 37. The gentle hot air passing through these rollers and pipes serves two important purposes: preliminary resin curing and pre-gelling: ensuring rapid preliminary curing of the resin-impregnated film and fibers before entering the main curing oven to prevent resin dripping; preheating and drying: preheating the materials and semi-finished products to reduce thermal shock upon entering the oven and to help remove any remaining trace amounts of moisture or solvent; secondary shaping: the fully cured slings undergo final shaping via the rear molding mold 45.

[0057] The traction mechanism 6 includes a traction base frame 51, on which several horizontally arranged adjusting slide shafts 54 are provided. Two symmetrically arranged slide frames 52 are slidably arranged on the several adjusting slide shafts 54. Two symmetrically arranged adjusting electric screws 53 are fixed at the upper end of the traction base frame 51. The slide frames 52 are fixedly connected to the shift seats of the adjusting electric screws 53 on the same side. Two pull wheels 48 are rotatably provided at the upper end of each slide frame 52. A traction track 49 is provided between the two pull wheels 48. The lower circumference of each traction track 49 is provided with a material placement protrusion 50. A traction motor is fixed at the lower end of each slide frame 52. The output shaft of the traction motor is fixedly connected to one of the traction wheels 48 on the same side.

[0058] The control system sends commands to the two adjusting electric screws 53, which rotate precisely, pushing or pulling the two sliding frames 52 to move synchronously in opposite directions along the adjusting sliding shaft 54. The movement of the sliding frames 52 drives the entire traction unit (traction wheel 48, traction track 49, and material placement protrusion 50) to move together, thereby precisely adjusting the clamping distance between the two traction tracks 49 to adapt to sling products of different widths. The traction motor starts, drives the traction wheel 48, and drives the traction track 49 to rotate. The traction track 49 clamps the sling, and the material placement protrusion 50 on its surface supports the sling, achieving constant speed traction of the sling.

[0059] The cutting mechanism 7 includes a cutter holder 58. The upper end of the cutter holder 58 is provided with an inverted U-shaped cutter frame 57. The middle part of the cutter frame 57 is fixed with a downward-extending electric push rod 55. A cutter 56 is fixed below the extension end of the electric push rod 55. The upper end of the cutter 56 is fixed with two left-right symmetrical vertical sliding shafts 59. The two vertical sliding shafts 59 are slidably mounted on the cutter frame 57.

[0060] Standby state: During normal traction, the lifting electric push rod 55 is in the retracted state, and the cutter 56 is raised to the highest point to clear the passage for the sling, allowing production to continue continuously; Trigger signal: When the length of the sling delivered by the traction mechanism 6 reaches the preset value, the measuring sensor (such as an encoder) sends a signal to the control system; Execute cutting: The control system immediately commands the lifting electric push rod 55 to extend instantaneously, pushing the cutter 56 to move vertically downward at high speed along the guide of the vertical sliding shaft 59 to cut the sling; Quick reset: After cutting is completed, the lifting electric push rod 55 retracts instantaneously, causing the cutter 56 to rise rapidly, leaving the cutting area, restoring the passage, and waiting for the next cutting command.

[0061] This process achieves a breakthrough in product performance through innovative multi-layer composite structures and precise material formulation. It utilizes a silicone core and a double-layer TPU coating structure, combined with fiber surface modification technology, to enhance interfacial bonding strength and insulation durability. Gradient curing ensures the product possesses comprehensive protective properties such as superhydrophobicity and UV resistance, meeting the stringent requirements of ultra-high voltage environments. The production line adopts a highly integrated and automated design, integrating impregnation, coating, curing, and traction processes through a skid-mounted base. A precise tension control system and multi-stage guiding mechanism ensure the stability of material processing, while a zoned temperature control and heat recovery system achieves efficient energy utilization. A unique adaptive traction mechanism and rapid cutting device ensure continuous, precise, and flexible production. This technology system achieves a harmonious balance between quality, efficiency, and environmental protection. Automated production increases product qualification rates, improves performance consistency, and enhances production efficiency compared to traditional processes. Closed-loop production and heat recycling reduce energy consumption and VOC emissions, combining economic benefits with environmental friendliness, providing reliable technical support for ultra-high voltage equipment manufacturing.

[0062] A surface coating device can also be added after step nine. Specifically, an additional coating device is designed at the outlet of the heating and curing mold 5 to simultaneously coat the surface of the formed sling with an anti-corrosion coating. This coating has superhydrophobic, anti-fouling, and UV-resistant properties.

[0063] Example 1: Insulating slings for ±1100kV UHVDC 1. Product Specifications: Model: JY-1100kV-DC, Rated Load: 8 tons, Structural Dimensions: 70mm wide × 30mm thick × 8m long, and Insulation Class: ±1100kV DC.

[0064] 2. Raw material preparation: (1) Core fiber: T300 carbon fiber and aramid are mixed and woven in a ratio of 3:7, and the fabric thickness is 0.5mm; (2) Reinforcing fiber: Dyneema SK75 ultra-high molecular weight polyethylene fiber; (3) Silicone rubber: Shin-Etsu KE-951-U liquid silicone; (4) TPU film: Bayer Desmopan 385E, thickness 0.18mm; (5) Resin system: epoxy resin (Nanya NPEL-128, 100 parts), curing agent (DDS, 28 parts), nano silica (Evonik AEROSIL R812, 5 parts) and ultraviolet absorber (1.0 part).

[0065] 3. Technological Process: 3.1 Core Material Preparation: The carbon fiber / aramid hybrid fabric was immersed in liquid silica gel under a vacuum of -0.098 MPa for 30 minutes, and then pre-dried at 65°C for 1 hour. Then, the four layers of impregnated fabric were stacked and vulcanized in a vulcanizing machine at 160°C and 1.2 MPa pressure for 20 minutes to obtain a vulcanized belt core material with a total thickness of 2.1 mm.

[0066] 3.2 Fiber Treatment: Dyneema fibers were surface-treated using oxygen plasma: power 300W, treatment time 3 minutes, oxygen flow rate 50 sccm. After treatment, the oxygen content on the fiber surface increased from 18.6% to 36.2%.

[0067] 3.3 Integrated Molding: The vulcanized core material is introduced into the molding production line with the following process parameters: Inner coating layer: top and bottom film width 67mm, side film width 27mm; Reinforcing fiber arrangement: 16 bundles on the top and bottom surfaces, 5 bundles on the left and right sides; Outer coating layer: top and bottom film width 70mm, side film width 30mm; Pultrusion speed: 1.0m / min; Curing temperature: 85℃ inlet zone, 145℃ in the middle zone, and 165℃ at the outlet zone. 3.4 Surface treatment: Apply SR / PU composite coating at the mold exit using roller coating method. The coating thickness is 0.05mm, and pre-cur at 80℃ for 45 seconds.

[0068] 3.5 Fixed-length cutting and end-joint connection: A servo-controlled hydraulic cutting system is used, with a cutting length accuracy of ±2mm. The end uses a TC4 titanium alloy connector, filled with Henkel Loctite EA-3432 epoxy structural adhesive, and cured at 80℃ for 2 hours.

[0069] 4. Performance test results: 4.1 Mechanical properties: Average breaking strength: 108 kN (135% of rated load) Elongation at break: 3.2% Cyclic load performance: After 5000 cycles of rated load, the strength retention rate is 98.5%.

[0070] 4.2 Electrical performance: ±1100kV DC withstand voltage test: Passed Power frequency dry-state flashover voltage: >1250kV Volume resistivity: 8.7 × 10¹ 4 Ω·m Surface resistivity: 5.3 × 10¹³ Ω 4.3 Environmental adaptability Damp heat cycling test (1000h): Strength retention rate 94%. UV aging (3000h): Color change ΔE < 2.0 Salt spray corrosion (2000h): No corrosion observed. High and low temperature alternation (-50℃ to +85℃, 100 cycles): No performance degradation. 4.4 Interface properties: interlaminar shear strength: 32MPa; 90° peel strength: 7.8N / mm.

[0071] Example 2: Insulating sling for 1000kV AC ultra-high voltage 1. Product Specifications: Model: JY-1000kV-AC, Rated load: 12 tons and Insulation class: 1000kV AC.

[0072] 2. Process change points: (1) Core fiber: T700 carbon fiber and Kevlar 49 are mixed in a 5:5 ratio. (2) Surface modification: Dopamine biomimetic modification was used, and the treatment time was 4 hours. (3) Reinforcing fiber: Zylon PBO fiber (4) Pultrusion speed: 0.6 m / min (5) Curing temperature: 95℃ at the inlet, 155℃ at the middle, and 175℃ at the outlet.

[0073] 3. Test Results: Power frequency withstand voltage: 1000kV / 1min pass Lightning impulse withstand: +2550kV / -2400kV pass Operating wave impact: 1800kV passed.

[0074] In summary, this application achieves continuous and automated production of insulating slings, increasing production efficiency by 3-5 times; the product has excellent interfacial bonding strength, with interlaminar shear strength exceeding 30 MPa; it exhibits superior insulation performance, meeting the requirements of UHV AC / DC projects; it demonstrates excellent resistance to environmental aging, significantly extending its service life; and it reduces VOC emissions by more than 80% during production, resulting in significant environmental benefits. The above embodiments fully demonstrate the technical feasibility and advancement of the method of this invention, and the performance indicators of the produced products all meet or exceed the requirements of UHV projects.

[0075] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. An integrated molding process for ultra-high voltage AC / DC insulating soft slings, characterized in that, Includes the following steps: Step 1, weaving textile layers: Weaving fibers to obtain fiber fabric layers; Step 2, Vacuum Impregnation: The fiber fabric layer is immersed in insulating liquid silicone under vacuum. The liquid silicone penetrates into the fiber fabric layer. After half an hour, it is taken out and dried to obtain a dried layer. Step 3, Layered vulcanization: Several dried layers are stacked together and placed inside the vulcanization equipment for vulcanization. After vulcanization, silicone interlayers are formed between the dried layers, and a silicone protective layer is formed on the outer surface after vulcanization, thus obtaining the vulcanized belt core material. Step 4, fiber pretreatment and surface modification: Select at least one of high-strength polyethylene fiber and poly(p-phenylenebenzobisoxazole) fiber as reinforcing fiber, and perform surface modification treatment on the fiber to improve its interfacial bonding force with the resin matrix; dry the modified fiber at a set temperature and roll it up for later use. Step 5, Prepare the impregnation resin solution: The impregnation resin solution comprises: Matrix resin: Low viscosity, high insulation performance epoxy resin system or special unsaturated polyester resin; Curing agent: 4,4'-diaminodiphenyl sulfone or corresponding anhydride curing agent, added at a mass ratio of resin to curing agent of 100:25 to 100:35; Moisture-proof reinforcement components: including but not limited to nano-silica and fumed silica hydrophobic fillers, accounting for 3%-8%; Functional additives: including but not limited to ultraviolet absorbers and antioxidants; Step 6, Impregnating the inner and outer coating layers: Using TPU film rolls of two different widths as the main body of the inner and outer coating layers, respectively, they are immersed into the impregnation resin liquid at the corresponding positions to obtain the inner impregnation layer and the outer impregnation layer. Step 7, Impregnating modified fibers: The modified fibers are rolled up and immersed in the impregnation resin solution at the corresponding positions to form impregnated fibers; Step 8, Integrated Molding: Inner coating: The vulcanized belt core material from step three is coated from the top and bottom and left and right sides of the vulcanized belt core material with two widths respectively through the inner impregnation layer from step six to obtain the first coating layer; Fiber coating: Several impregnated fibers from step seven are coated from the top and bottom and left and right sides of the first coating layer to obtain a fiber coating layer; Outer coating: The fiber coating layer is coated from the top and bottom and left and right sides of the fiber coating layer with two widths respectively through the outer impregnation layer in step six to obtain the second coating layer; Step 9, Heating and Curing: The belt with the second coating layer is introduced into the heating and curing mold. The temperature of the heating and curing mold is controlled in zones. Under the action of the traction mechanism, the belt is compressed and heated in the mold to complete the gelation and curing of the resin. Step 10, Continuous traction and fixed-length cutting: The cured and coated continuous sling is pulled out at a constant speed by the traction mechanism; Step 11, Lightweight Integrated End Connection: A lightweight metal alloy (such as titanium alloy or titanium fiber metal alloy) end connector with topology optimization design is used; after pre-treating the cut end of the sling obtained in Step 10, it is inserted into the slot of the end connector, and high-strength epoxy resin structural adhesive is injected into the slot. After curing, a high-strength, integrated connection between the sling and the end is achieved by "adhesive riveting composite".

2. The integrated molding process for an ultra-high voltage AC / DC insulating soft sling according to claim 1, characterized in that, In step one, the fiber used is at least one of carbon fiber and modified aramid fiber, or a mixture of them in a specific ratio such as 3:7 to 5:5, to balance strength, modulus, insulation and cost; the thickness of the fiber fabric layer in step one is 0.5±0.05 mm.

3. The integrated molding process for an ultra-high voltage AC / DC insulating soft sling according to claim 2, characterized in that, In step three, the thickness of the silicone interlayer is 0.3±0.05 mm, and the thickness of the silicone protective layer is 0.5±0.05 mm.

4. The integrated molding process for an ultra-high voltage AC / DC insulating soft sling according to claim 3, characterized in that, The modification methods in step four include dopamine biomimetic modification or plasma treatment. Dopamine biomimetic modification involves immersing the fiber in a dopamine / Tris hydrochloride buffer solution with pH=8.5 and stirring at 30°C for 2-5 hours to uniformly coat the fiber surface with a polydopamine film, increasing surface roughness and reactive sites. Plasma treatment involves using oxygen or ammonia plasma to treat the fiber for a short time, introducing oxygen- or nitrogen-containing polar functional groups.

5. The integrated molding process for an ultra-high voltage AC / DC insulating soft sling according to claim 4, characterized in that, In step nine, the temperature of the mold is 80-100°C in the inlet zone, 130-160°C in the middle zone, and 160-180°C in the outlet zone.

6. The integrated molding process for an ultra-high voltage AC / DC insulating soft sling according to claim 5, characterized in that, The equipment used in steps five to eleven includes a skid-mounted base (1). The upper end of the skid-mounted base (1) is provided with, from front to back, an impregnation molding mechanism (2), a fiber impregnation mechanism (3), a fiber forming mechanism (4), an impregnation molding mechanism (2), a heat curing mold (5), a traction mechanism (6), and a cutting mechanism (7). The impregnation molding mechanism (2) includes a layer impregnation frame (8) and a layer impregnation tank (17). Both the layer impregnation frame (8) and the layer impregnation tank (17) are fixed on the skid. At the upper end of the base (1), the impregnation tank (17) is located inside the impregnation frame (8). The rear side of the impregnation frame (8) is provided with two symmetrical hollow side rollers (10) and two symmetrical hollow pressure rollers (9). A feeding pressure cavity is formed between the two hollow side rollers (10) and the two hollow pressure rollers (9). The front side of the impregnation frame (8) is provided with two symmetrical side roll rollers (12) and two symmetrical face roll rollers (13). Side roll films (14) can be detachably installed on the side roll rollers (12). 5) A roll film (14) is detachably mounted on the roll film (13). A roll film (16) is rotatably mounted inside the immersion tank (17). A guide assembly (11) is symmetrically arranged on the front and rear sides of the upper end of the immersion tank (17). A first tensioning frame (18) is provided on the immersion tank (17). The first tensioning frame (18) is located between the roll film (16) and the rear guide assembly (11). The guide assembly (11) includes a side guide frame (19). The side guide frame (19) is fixed to the immersion tank (13). At the upper end of 17), the inner side of the side guide frame (19) is provided with two left-right symmetrical side guide double rollers (21) and two up-down symmetrical horizontal guide double rollers (20). The inner middle of the side guide frame (19) is provided with two left-right symmetrical variable angle seats (22). The variable angle seats (22) are rotatably provided with variable angle double rollers (23) inside. The lower inner part of the side guide frame (19) is fixed with two left-right symmetrical lower guide seats (25). The lower guide seats (25) are rotatably provided with lower guide double rollers (24) inside.

7. The integrated molding process for an ultra-high voltage AC / DC insulating soft sling according to claim 6, characterized in that, The fiber impregnation mechanism (3) includes a fiber impregnation frame (26) and a fiber impregnation assembly (27). The fiber impregnation frame (26) is fixed on the upper end of the skid-mounted base (1), and the fiber impregnation assembly (27) is set on the upper end of the skid-mounted base (1). The front side of the fiber impregnation frame (26) is provided with two sets of left-right symmetrical fiber side rolls (28) and two sets of top-bottom symmetrical fiber surface rolls (29). The rear side of the fiber impregnation frame (26) is provided with two left-right symmetrical hollow side fiber guide rollers (31) and two sets of top-bottom symmetrical hollow surface fiber guide rollers (30). The fiber impregnation assembly (27) includes a fiber impregnation box (32). The fiber impregnation box (32) is provided with a fiber impregnation roller (35) rotating inside. The front and rear sides of the upper end of the fiber impregnation box (32) are provided with two sets of symmetrically arranged dividing rods (34). The fiber impregnation box (32) is provided with a second tensioning frame (33). The second tensioning frame (33) is located between the fiber impregnation roller (35) and a set of dividing rods (34) on the rear side.

8. The integrated molding process for an ultra-high voltage AC / DC insulating soft sling according to claim 7, characterized in that, The fiber forming mechanism (4) includes a fiber forming mold (41), which is located at the upper end of the skid-mounted base (1). The fiber forming mold (41) has a main channel (38) inside, which is wedge-shaped with a larger front and a smaller back. The inner side of the fiber forming mold (41) has two sets of vertically symmetrical surface guide channels (39) and two sets of horizontally symmetrical side guide channels (36). The surface guide channels (39) and the side guide channels (36) penetrate the fiber forming mold (41). The front ends of the two sets of surface guide channels (39) are respectively facing the hollow surface fiber guide roller (30), and the front ends of the two sets of side guide channels (36) are respectively facing the hollow side fiber guide roller (31). The end of the fiber forming mold (41) is provided with a pressing port (40). The ends of the side guide channels (36) and surface guide channels (39) are located at the pressing port (40). The left and right sides of the fiber forming mold (41) are provided with two sets of symmetrically arranged air inlet pipes (37), and the air inlet pipes (37) are connected to the main channel (38).

9. The integrated molding process for an ultra-high voltage AC / DC insulating soft sling according to claim 8, characterized in that, The heat curing mold (5) includes a traction frame (43), which is located at the upper end of the skid-mounted base (1). A heater (42) and a blower (47) are provided on the lower side of the traction frame (43). An electric conveyor belt (44) is provided on the traction frame (43). An oven is provided in the middle of the traction frame (43). Both the traction frame (43) and the electric conveyor belt (44) pass through the oven. The air inlet of the blower (47) is connected to the air outlet of the heater (42), and the air outlet of the blower (47) is connected to the lower end of the oven. The upper end of the traction frame (43) is fixed with two symmetrically arranged molding models (45). The two molding models (45) are respectively connected to the front and rear sides of the oven. The upper end of the oven is provided with a filter exhaust box (46) connected to it. The upper end of the oven is provided with an exhaust fan. The air inlet of the exhaust fan is connected to the air outlet of the filter exhaust box (46). The air outlet of the exhaust fan is connected to the hollow pressure roller (9), the hollow side roller (10), the hollow surface fiber guide roller (30), the hollow side fiber guide roller (31) and the air inlet pipe (37) through pipes respectively.

10. The integrated molding process for an ultra-high voltage AC / DC insulating soft sling according to claim 9, characterized in that, The traction mechanism (6) includes a traction base frame (51), on which several horizontally arranged adjusting slide shafts (54) are provided. Two symmetrically arranged slide frames (52) are slidably arranged on the several adjusting slide shafts (54). Two symmetrically arranged adjusting electric screws (53) are fixed at the upper end of the traction base frame (51). The slide frames (52) are fixedly connected to the shift seats of the adjusting electric screws (53) on the same side. Two pull wheels (48) are rotatably provided at the upper end of each slide frame (52). A traction track (49) is provided between the two pull wheels (48). The lower circumference of the traction track (49) is provided with a material placement protrusion. 50), the lower end of the slide frame (52) is fixed with a traction motor, and the output shaft of the traction motor is fixedly connected to one of the traction wheels (48) on the same side; the cutting mechanism (7) includes a cutter seat (58), the upper end of the cutter seat (58) is provided with an inverted U-shaped cutter frame (57), the middle part of the cutter frame (57) is fixed with a downward-extending electric push rod (55), the lower end of the extension of the electric push rod (55) is fixed with a cutter (56), the upper end of the cutter (56) is fixed with two left-right symmetrical vertical slide shafts (59), and the two vertical slide shafts (59) are slidably arranged on the cutter frame (57).

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