Wear-resistant and corrosion-resistant cable insulating material and cable preparation method

Abstract

The invention discloses a wear-resistant and corrosion-resistant cable insulating material and a cable preparation method. The insulating material takes a blend of isocyanate modified chlorosulfonated polyethylene (CSM) and polyurethane (PU) as a base material; a composite nano reinforced filler modified by a silane coupling agent KH-550, a polytetrafluoroethylene (PTFE)-polyether-ether-ketone (PEEK) composite wear-resistant agent and a phenol-phosphite composite anti-aging agent are added, and a two-stage vacuum mixing and precise temperature control extrusion process is carried out to prepare the composite wear-resistant material. The cable insulation material aims at solving the problems that an existing cable insulation material is difficult to consider both wear resistance and chemical corrosion resistance in a severe environment and short in service life. The cable is suitable for mobile cables in severe environments such as mining machinery, harbor machinery, engineering vehicles and the like, and has remarkable practicability and economic value.

Description

Technical Field

[0001] This invention belongs to the technical field of cable insulation materials, specifically relating to a wear-resistant and corrosion-resistant cable insulation material and a cable preparation method. Background Technology

[0002] Cable insulation material is a core component that ensures the electrical insulation performance and service life of cables. Especially in applications such as mining machinery, port machinery, and engineering vehicles, cables need to withstand multiple tests such as frequent friction, oil erosion, acid and alkali corrosion, and damp heat aging, which puts forward stringent requirements on the wear resistance, chemical corrosion resistance, and aging resistance of insulation materials.

[0003] In existing technologies, cable insulation materials mostly use a single polymer base material (such as polyethylene, nitrile rubber, or simple polyurethane), and are modified with a single filler. For example, some patents use polyethylene blended with ethylene-vinyl acetate copolymer, adding inorganic fillers to improve corrosion resistance, but the wear resistance is insufficient; other patents use nitrile rubber as the base material, adding carbon black or nano-calcium carbonate to enhance wear resistance, but the acid and alkali resistance and hydrolysis resistance are limited. In addition, existing technologies have the following defects: 1) Poor compatibility of the base material makes it difficult to synergistically improve the mechanical properties and environmental resistance of the material; 2) Nanofillers are prone to agglomeration and uneven dispersion, failing to fully exert their reinforcing effect; 3) Anti-aging agents are mostly of a single type, making it difficult to resist multiple aging factors in harsh environments; 4) The mixing process is mostly single-stage, which easily leads to insufficient dispersion of fillers or degradation of the base material, affecting the stability of the finished product performance.

[0004] For example, patent CN102360600A discloses a cold-resistant, wear-resistant, flexible, and salt spray-resistant navigation composite cable. Its insulation layer uses PTFE or soft PVC elastomer, and the sheath layer uses silicone rubber. However, the oil resistance and acid and alkali resistance of this material are limited, and PTFE is difficult to process and has high cost. Patent CN120157833A discloses a high-toughness flame-retardant polyurethane cable insulation layer material. The flame retardancy is improved by grafting polyols with phosphorus-containing compounds, but the wear resistance and chemical corrosion resistance have not been specifically optimized. Summary of the Invention

[0005] To address the aforementioned problems, the present invention aims to provide a wear-resistant and corrosion-resistant cable insulation material and cable preparation method that can achieve a synergistic improvement in the material's wear resistance, chemical corrosion resistance, and aging resistance, meeting the usage requirements of mobile cables in harsh environments.

[0006] The objective of this invention is achieved through the following technical solution: A wear-resistant and corrosion-resistant cable insulation material, by weight, comprises the following components: 100 parts of modified PU / CSM blend base material, 5-15 parts of composite nano-reinforcing filler, 3-8 parts of composite wear-resistant agent, 1-3 parts of composite anti-aging agent, and 0.5-2 parts of silane coupling agent; the modified PU / CSM blend base material is composed of 60-80 parts of polyurethane (PU) and 20-40 parts of isocyanate-modified chlorosulfonated polyethylene (CSM); the composite nano-reinforcing filler is a compound of nano-silica powder and nano-alumina modified with silane coupling agent KH-550, wherein the nano-silica powder is 3-9 parts and the nano-alumina is 2-6 parts; the composite wear-resistant agent is a compound of polytetrafluoroethylene (PTFE) powder and polyetheretherketone (PEEK) powder, wherein the PTFE powder is 2-5 parts and the PEEK powder is 1-3 parts.

[0007] A method for preparing a wear-resistant and corrosion-resistant cable includes the following steps: S1. Preparation of modified CSM: CSM and isocyanate coupling agent are mixed at a weight ratio of 100:1~3 and stirred at 60~80℃ for 1~2h to obtain isocyanate modified CSM; S2. Two-stage vacuum mixing: Add PU and modified CSM to a vacuum mixer. The first stage mixing temperature is 100~120℃, the rotation speed is 30~50r / min, and the mixing time is 10~15min. Then add composite nano-reinforcing filler, composite wear-resistant agent, composite anti-aging agent and silane coupling agent. The second stage mixing temperature is 130~150℃, the rotation speed is 60~80r / min, the vacuum degree is -0.08~-0.06MPa, and the mixing time is 15~20min to obtain the compound. S3. Granulation: The compounded rubber is fed into a single-screw granulator, the granulation temperature is 140~160℃, the screw speed is 40~60r / min, and insulating material granules are obtained; S4. Extrusion molding: The insulating material granules obtained in step S3 are fed into the cable extruder. The temperature of each section of the screw is controlled as follows: feeding section 120~130℃, compression section 140~150℃, homogenization section 150~160℃, die head temperature 155~165℃, screw speed 20~40r / min. The extruded material is coated on the conductor surface and cooled by water cooling at 20~30℃ to obtain a wear-resistant and corrosion-resistant cable.

[0008] The polyurethane (PU) has a number-average molecular weight of 8,000 to 12,000.

[0009] The particle size of the nano-silicon powder is 50~80nm, and the particle size of the nano-alumina is 50~100nm.

[0010] The PTFE micro powder has a particle size of 1~3μm, and the PEEK micro powder has a particle size of 3~8μm.

[0011] The composite anti-aging agent is composed of 0.5-1.5 parts of phenolic antioxidant, 0.3-1 parts of phosphite antioxidant, and 0.2-0.5 parts of ultraviolet absorber; the phenolic antioxidant is Irganox1010, the phosphite antioxidant is Ultranox626, and the ultraviolet absorber is 2-hydroxy-4-methoxybenzophenone.

[0012] The silane coupling agent is KH-550 or KH-560.

[0013] The isocyanate coupling agent mentioned in step S1 is toluene diisocyanate (TDI) or diphenylmethane diisocyanate (MDI).

[0014] In step S2, the mixing chamber pressure of the vacuum mixer is maintained at 0.3~0.5MPa.

[0015] The conductor mentioned in step S4 is a tin-plated soft copper wire with a conductor stranding pitch ratio of 11 to 14.

[0016] The beneficial effects of this invention are: By blending isocyanate-modified CSM with PU, the technical problem of poor compatibility of traditional PU / CSM was solved; the modified nano-silica micropowder-alumina composite filler and PTFE-PEEK composite wear-resistant agent were used in synergy to achieve a synergistic improvement in wear resistance and chemical corrosion resistance; the combination of two-stage vacuum mixing and precision extrusion process ensured uniform dispersion of filler and high material density.

[0017] By employing a two-stage vacuum mixing and temperature gradient extrusion process involving modified base material, composite filler, and composite additives, the wear resistance, oil resistance, and acid and alkali resistance of the material are improved. Detailed Implementation

[0018] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0019] It should be understood that the structures, proportions, sizes, etc., depicted in this specification are merely for illustrative purposes and to facilitate understanding and reading by those skilled in the art. They are not intended to limit the conditions under which the invention can be implemented and therefore have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and purpose of the invention, should still fall within the scope of the technical content disclosed in this invention. Furthermore, terms such as "upper," "lower," "left," "right," and "middle" used in this specification are merely for clarity and not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention's implementation. Example 1

[0020] A wear-resistant and corrosion-resistant cable insulation material, by weight parts: 100 parts of modified PU / CSM blend base: 70 parts PU (number average molecular weight 10000) and 30 parts TDI modified CSM; 8 parts of composite nano-reinforced filler: 5 parts of KH-550 modified nano-silica powder (60nm) and 3 parts of nano-alumina (80nm); 5 parts composite wear-resistant agent: 3 parts PTFE micro powder (2μm) and 2 parts PEEK micro powder (5μm); Two parts of compound anti-aging agent: 1 part Irganox 1010, 0.6 parts Ultranox 626, and 0.4 parts 2-hydroxy-4-methoxybenzophenone; 1 part of silane coupling agent KH-550.

[0021] A method for preparing a wear-resistant and corrosion-resistant cable: S1. Preparation of modified CSM: CSM and TDI are mixed at a weight ratio of 100:2 and stirred at 70°C for 1.5 h to obtain TDI modified CSM; S2. Two-stage vacuum mixing: Add PU and modified CSM to a vacuum mixer. In the first stage, mix at 110°C and 40r / min for 12min. Add the remaining components and mix at 140°C and 70r / min with a vacuum of -0.07MPa for 18min. S3. Granulation: Single screw granulator temperature 150℃, screw speed 50r / min, granulation; S4. Extrusion molding: Temperature of each section of the cable extruder: feeding section 125℃, compression section 145℃, homogenization section 155℃, die head temperature 160℃, screw speed 30r / min, conductor is 40 / 0.25mm tin-plated soft copper wire (stretch pitch ratio 12 times), water cooling temperature 25℃. Example 2

[0022] A wear-resistant and corrosion-resistant cable insulation material, by weight parts: 100 parts of modified PU / CSM blend base: 60 parts PU (number average molecular weight 8000) and 40 parts MDI modified CSM; 12 parts of composite nano-reinforced filler: 7 parts of KH-550 modified nano-silica powder (50nm) and 5 parts of nano-alumina (50nm); 7 parts of composite wear-resistant agent: 4 parts of PTFE micro powder (1μm) and 3 parts of PEEK micro powder (3μm); 2.5 parts of compound anti-aging agent: 1.2 parts of Irganox 1010, 0.8 parts of Ultranox 626, and 0.5 parts of 2-hydroxy-4-methoxybenzophenone; 1.5 parts of silane coupling agent KH-560.

[0023] The preparation method of Example 2 differs from that of Example 1 only in that: the isocyanate coupling agent in step S1 is MDI; the mixing temperature in the first stage of step S2 is 100℃ and the rotation speed is 35r / min, and the mixing temperature in the second stage is 135℃ and the rotation speed is 65r / min. Example 3

[0024] A wear-resistant and corrosion-resistant cable insulation material, by weight parts: 100 parts of modified PU / CSM blend base: 80 parts PU (number average molecular weight 12000) and 20 parts TDI modified CSM; Five parts of composite nano-reinforced filler: three parts of KH-550 modified nano-silica powder (80nm) and two parts of nano-alumina (100nm); Composite wear-resistant agent 3 parts: PTFE micro powder (3μm) 2 parts, PEEK micro powder (8μm) 1 part; 1.5 parts of compound anti-aging agent: 0.8 parts of Irganox 1010, 0.5 parts of Ultranox 626, and 0.2 parts of 2-hydroxy-4-methoxybenzophenone; 0.8 parts of silane coupling agent KH-550.

[0025] The preparation method of Example 3 differs from that of Example 1 only in that: in step S4, the screw speed is 25 r / min and the die head temperature is 155℃.

[0026] The performance of the cable insulation layers prepared in Examples 1-3 was tested, and the results are shown in Table 1 below:

[0027] Table 1 As shown in Table 1, this invention achieves a synergistic breakthrough in the wear resistance, oil resistance, acid and alkali resistance, and aging resistance of cable insulation materials through formula innovation (modified base material, composite filler, composite additive) and process optimization (two-stage vacuum mixing and precision extrusion). All core indicators are significantly better than industry standards.

[0028] In the description of this invention, it should be noted that, unless otherwise expressly specified and limited, the terms "connected" or "linked" should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral connection; it can refer to a mechanical connection or an electrical connection; it can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. It should be noted that the terms "comprising," "including," or any other variations are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.

[0029] The scope of protection of this invention is not limited to the technical solutions disclosed in the specific embodiments. Any modifications, equivalent substitutions, improvements, etc., made to the above embodiments based on the technical essence of this invention shall fall within the scope of protection of this invention.

Claims

1. A wear-resistant and corrosion-resistant cable insulation material, characterized in that: The product comprises, by weight, the following components: 100 parts of modified PU / CSM blend base material, 5-15 parts of composite nano-reinforcing filler, 3-8 parts of composite wear-resistant agent, 1-3 parts of composite anti-aging agent, and 0.5-2 parts of silane coupling agent; the modified PU / CSM blend base material is composed of 60-80 parts of polyurethane (PU) and 20-40 parts of isocyanate-modified chlorosulfonated polyethylene (CSM); the composite nano-reinforcing filler is a compound of nano-silica powder and nano-alumina modified with silane coupling agent KH-550, wherein the nano-silica powder is 3-9 parts and the nano-alumina is 2-6 parts; the composite wear-resistant agent is a compound of polytetrafluoroethylene (PTFE) powder and polyetheretherketone (PEEK) powder, wherein the PTFE powder is 2-5 parts and the PEEK powder is 1-3 parts.

2. A method for preparing a wear-resistant and corrosion-resistant cable, characterized in that: Includes the following steps: S1. Preparation of modified CSM: CSM and isocyanate coupling agent are mixed at a weight ratio of 100:1~3 and stirred at 60~80℃ for 1~2h to obtain isocyanate modified CSM; S2. Two-stage vacuum mixing: Add PU and modified CSM to a vacuum mixer. The first stage mixing temperature is 100~120℃, the rotation speed is 30~50r / min, and the mixing time is 10~15min. Then add composite nano-reinforcing filler, composite wear-resistant agent, composite anti-aging agent and silane coupling agent. The second stage mixing temperature is 130~150℃, the rotation speed is 60~80r / min, the vacuum degree is -0.08~-0.06MPa, and the mixing time is 15~20min to obtain the compound. S3. Granulation: The compounded rubber is fed into a single-screw granulator, the granulation temperature is 140~160℃, the screw speed is 40~60r / min, and insulating material granules are obtained; S4. Extrusion molding: The insulating material granules obtained in step S3 are fed into the cable extruder. The temperature of each section of the screw is controlled as follows: feeding section 120~130℃, compression section 140~150℃, homogenization section 150~160℃, die head temperature 155~165℃, screw speed 20~40r / min. The extruded material is coated on the conductor surface and cooled by water cooling at 20~30℃ to obtain a wear-resistant and corrosion-resistant cable.

3. The wear-resistant and corrosion-resistant cable insulation material according to claim 1, characterized in that: The polyurethane (PU) has a number-average molecular weight of 8,000 to 12,000.

4. The wear-resistant and corrosion-resistant cable insulation material according to claim 1, characterized in that: The particle size of the nano-silicon powder is 50~80nm, and the particle size of the nano-alumina is 50~100nm.

5. The wear-resistant and corrosion-resistant cable insulation material according to claim 1, characterized in that: The PTFE micro powder has a particle size of 1~3μm, and the PEEK micro powder has a particle size of 3~8μm.

6. The wear-resistant and corrosion-resistant cable insulation material according to claim 1, characterized in that: The composite anti-aging agent is composed of 0.5-1.5 parts of phenolic antioxidant, 0.3-1 parts of phosphite antioxidant, and 0.2-0.5 parts of ultraviolet absorber; the phenolic antioxidant is Irganox1010, the phosphite antioxidant is Ultranox626, and the ultraviolet absorber is 2-hydroxy-4-methoxybenzophenone.

7. The wear-resistant and corrosion-resistant cable insulation material according to claim 1, characterized in that: The silane coupling agent is KH-550 or KH-560.

8. The method for preparing the wear-resistant and corrosion-resistant cable according to claim 2, characterized in that: The isocyanate coupling agent mentioned in step S1 is toluene diisocyanate (TDI) or diphenylmethane diisocyanate (MDI).

9. The method for preparing the wear-resistant and corrosion-resistant cable according to claim 2, characterized in that: In step S2, the mixing chamber pressure of the vacuum mixer is maintained at 0.3~0.5MPa.

10. The method for preparing the wear-resistant and corrosion-resistant cable according to claim 2, characterized in that: The conductor mentioned in step S4 is a tin-plated soft copper wire with a conductor stranding pitch ratio of 11 to 14.

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