Signal cable, preparation method and use method

Abstract

The invention discloses a signal cable and a preparation method and a use method, the signal cable sequentially comprises a cable core, an inner sheath, a composite function layer and an outer protective sleeve from inside to outside, and the composite function layer at least comprises a first sub-layer and a second sub-layer which are distributed in the radial direction. According to the invention, through double superposition of static coding and dynamic response, identification equipment must simultaneously verify an identity password and a state password, so that the counterfeiting difficulty and cost are greatly increased; the cable is upgraded into an intelligent terminal with state sensing capability, and the electrified state, the load condition and the like of the cable can be sensed in a non-contact manner through an external optical means without cutting off power or contacting a conductor, so that a brand new technical means is provided for routing inspection, operation and maintenance of an intelligent power grid; the dynamic response signal can be used as a visual or optical beacon, the target cable can be quickly locked in a complex background, accurate identification is carried out in combination with static coding, and the problems of difficult identification and inaccurate positioning in a complex environment are solved.

Description

Technical Field

[0001] This invention belongs to the technical field, specifically relating to a signal cable, its preparation method, and its usage method. Background Technology

[0002] In modern communications, data centers, and sophisticated electronic systems, signal cables not only need to achieve efficient and stable signal transmission, but their manageability is also becoming increasingly important. Traditional signal cables typically focus only on electrical performance, and their physical identification relies on external labels or surface printing. These labels are easily worn or detached during installation, use, and maintenance, leading to the loss of asset information and causing significant difficulties in operation and maintenance management.

[0003] Currently, the industry mainly uses static coded patterns. Although they can provide identification, they cannot reflect the current operating status of the cable (such as whether it is energized or overloaded). They have limited functionality, and static codes are at risk of being counterfeited. For high-security applications, their anti-counterfeiting capabilities are still insufficient.

[0004] Therefore, there is an urgent need for an intelligent cable solution that can combine cable identity information with real-time status information and has multi-dimensional anti-counterfeiting and collaborative recognition functions. Summary of the Invention

[0005] To address the problems in the prior art, the present invention aims to provide a signal cable, its preparation method, and its usage method. By constructing a composite functional layer with a multi-layer structure, static encoding is combined with field-induced dynamic response, achieving dual-mode collaborative identification of "identity + status", which greatly improves the identification dimensionality and security.

[0006] To achieve the above objectives and technical effects, the technical solution adopted by this invention is as follows: A signal cable includes, from the inside out, a cable core, an inner sheath, and an outer protective sheath, wherein a composite functional layer is provided between the inner sheath and the outer protective sheath, and the composite functional layer includes at least a first sub-layer and a second sub-layer distributed radially. The first sublayer is composed of a transparent or translucent first composite material, wherein optical feature particles are dispersed therein, arranged along the cable axis to form a first machine-readable coded pattern; The second sublayer is composed of a transparent second composite material in which field-responsive optical material is dispersed, the field-responsive optical material being used to change its optical properties under external physical field excitation to form a dynamic optical signal superimposed on the first machine-readable coded pattern; The outer protective cover shall at least cover the area of ​​the coded pattern with a light-transmitting material.

[0007] Furthermore, the field-responsive optical material is one or more of electrochromic materials, thermochromic materials, and piezochromic materials, and the external physical field is an electrical signal applied to the signal conductor of the cable core, a temperature change of the cable body, or external mechanical stress.

[0008] Furthermore, a first type of nano-reinforcing agent is dispersed in the first sublayer, and a second type of nano-reinforcing agent is dispersed in the second sublayer.

[0009] Furthermore, the first type of nano-reinforcing agent is a rigid nanoparticle, and the second type of nano-reinforcing agent is a conductive nanomaterial.

[0010] Furthermore, the rigid nanoparticles are nano-silica, and the conductive nanomaterials are single-walled or double-walled carbon nanotubes.

[0011] Furthermore, the second sublayer also includes multiple response blocks spaced apart along the cable axis, each of which contains different types or concentrations of field-responsive optical materials to generate stepped dynamic optical signals under external physical field excitation of different intensities.

[0012] Furthermore, the first machine-readable encoded pattern is a static optical QR code or barcode containing cable identification information and specifications.

[0013] Furthermore, the dynamic optical signal is a change in color, a change in transparency, or the appearance and disappearance of a pattern.

[0014] This invention also discloses a method for manufacturing a signal cable, comprising the following steps: Step 1): Prepare the cable core; Step 2) Extruding the inner sheath onto the outside of the cable core; Step 3) Melt and mold a transparent or translucent first composite material onto the outside of the inner sheath, and simultaneously form a first machine-readable coded pattern composed of optical feature particles by molding or laser etching to form the first sublayer; The transparent second composite material is then melted and molded onto the outside of the first sublayer to form the second sublayer; Step 4) Extrude an outer protective sleeve outside the second sublayer.

[0015] This invention also discloses a method of using a signal cable, comprising the following steps: Step 1: Using an external reading device to read the static first machine-readable code pattern composed of optical feature particles arranged in the first sub-layer through the outer protective sleeve, the cable's identity information and specification parameters are obtained; Step 2: Apply a detection electrical signal to the signal conductor of the cable core, or, under the natural working condition of the cable, use the external reading device to monitor the dynamic optical signal generated by the second sublayer due to electrical, thermal, or pressure excitation; Step 3: Combining the static first machine-readable encoded pattern with the dynamic optical signal, a comprehensive judgment and identification is made on the authenticity, energized status or overload condition of the cable.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) Multidimensional recognition with strong anti-counterfeiting: Through the dual superposition of static coding and dynamic response, the recognition device must verify the "identity password" and "status password" at the same time, which greatly increases the difficulty and cost of counterfeiting; (2) Status visualization and intelligent monitoring: The cable is upgraded from a simple power / signal transmission medium to an intelligent terminal with status perception capability. Without powering off or contacting the conductor, the cable's energized status and load status can be perceived non-contactly through external optical means, providing a brand-new technical means for the inspection and maintenance of smart grids. (3) Synergistic enhancement and high recognition accuracy: The dynamic response signal can be used as a visual or optical "beacon" to help the recognition device quickly lock the target cable in complex backgrounds such as messy cables, and combine it with static coding for accurate recognition, which solves the problems of difficult recognition and inaccurate positioning in complex environments; (4) Structural compatibility and easy manufacturing: The composite functional layer is only added to the original cable structure, and both layers can be realized by mature extrusion and molding / laser processes. It has good compatibility with existing cable production processes and is easy to promote industrialization. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the present invention. Detailed Implementation

[0018] The present invention will now be described in detail so that its advantages and features can be more easily understood by those skilled in the art, thereby providing a clearer and more explicit definition of the scope of protection of the present invention.

[0019] The following provides a brief overview of one or more aspects to offer a basic understanding of them. This overview is not an exhaustive summary of all conceived aspects, nor is it intended to identify key or decisive elements of all aspects, nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form to prepare for the more detailed descriptions that follow.

[0020] like Figure 1As shown, the present invention discloses a signal cable with dynamic collaborative response and embedded identification function. It includes a cable core 1, an inner sheath 2 and an outer protective sheath 3 from the inside to the outside. A composite functional layer 4 is provided between the inner sheath 2 and the outer protective sheath 3. The composite functional layer 4 includes at least a first sub-layer and a second sub-layer distributed radially. The first sublayer is composed of a transparent or translucent first composite material, in which optical feature particles (such as high-reflectivity glass microspheres) are dispersed, arranged along the cable axis to form a first machine-readable coded pattern; this layer is mainly used to provide static, unalterable basic identity information, equivalent to the cable's "ID card"; The second sublayer is composed of a transparent second composite material in which field-responsive optical material is dispersed. The field-responsive optical material is used to change its optical properties under external physical field excitation to form a dynamic optical signal superimposed on the first machine-readable coded pattern; this layer is equivalent to the "status indicator" of the cable. The outer protective cover 3 shall cover at least the area of ​​the coded pattern with a light-transmitting material to ensure that the optical signal can be effectively read by an external reading device.

[0021] In some embodiments, the cable core 1 includes four conductor units, each conductor unit including a wrapping tape 13 and two signal conductors 11 disposed therein, the signal conductors 11 being covered with an insulation layer 12.

[0022] In some specific embodiments, the signal conductor 11 is a solid copper conductor, the insulation layer 12 is a foamed polyethylene insulation layer, the wrapping tape 13 is an aluminum foil longitudinally wrapped shielding tape, the inner sheath 2 is a thin PVC inner sheath, and the outer protective sheath 3 is a semi-transparent PVC sheath.

[0023] In some embodiments, the field-responsive optical material is one or more of the following: electrochromic material, thermochromic material, and piezochromic material.

[0024] In some embodiments, the external physical field is an electrical signal applied to the signal conductor 11 of the cable core 1, a temperature change in the cable body, or external mechanical stress. For example, when current flows through the signal conductor 11, the electric field around it or the generated Joule heating can excite optical changes in the second sublayer.

[0025] In some embodiments, a first type of nano-reinforcing agent is also dispersed in the first sublayer.

[0026] In some specific implementations, the first type of nano-reinforcing agent is rigid nanoparticles.

[0027] In some specific implementations, the rigid nanoparticles are nano-silica, used to improve the dimensional stability and scratch resistance of the first sublayer.

[0028] In some embodiments, a second type of nano-reinforcing agent is also dispersed in the second sublayer.

[0029] In some specific implementations, the second type of nano-reinforcing agent is a conductive nanomaterial.

[0030] In some specific implementations, the conductive nanomaterial is a single-walled or double-walled carbon nanotube. The uniformly dispersed carbon nanotubes can form a micro-conductive network in the second sublayer. When the cable is energized, this network can assist in the distribution of the electric field or generate a micro-thermal field, thereby more effectively stimulating the uniformly distributed color-changing material to produce a response.

[0031] In some implementations, to achieve richer status indication, the second sublayer may also include multiple response blocks spaced apart along the cable axis. Each response block contains a different type or concentration of field-responsive optical material to generate a stepped dynamic optical signal under external physical field excitation of varying intensities. For example, three blocks can be set up to correspond to normal load (no color change), 20% overload (turns yellow), and 50% overload (turns red), respectively, thereby intuitively indicating the degree of overload.

[0032] In some implementations, the first machine-readable coded pattern is a static optical QR code or barcode containing cable identification information and specifications.

[0033] In some implementations, the dynamic optical signal is a change in color, a change in transparency, or the appearance and disappearance of a pattern.

[0034] This invention also discloses a method for manufacturing a signal cable, comprising the following steps: Step 1) Prepare cable core 1; Step 2) Extrude the inner sheath 2 onto the outside of the cable core 1; Step 3) Melt and mold a transparent or translucent first composite material onto the outer side of the inner sheath 2, and simultaneously form a first machine-readable coded pattern composed of optical feature particles by molding or laser etching to form the first sublayer; The transparent second composite material is then melted and molded onto the outside of the first sublayer to form the second sublayer; Step 4) Extrude the outer protective sleeve 3 outside the second sublayer.

[0035] In some embodiments, in step 3), 72-88 parts by weight of thermoplastic polyurethane, 5-18 parts by weight of optical feature particles, 3-9 parts by weight of the first type of nano-reinforcing agent, and 1-4 parts by weight of the interface modifier (such as silane coupling agent) are melt-blended and then extruded onto the outer side of the inner sheath 2. During the extrusion molding process, a die roller with a micron-level uneven structure is used to press the surface of the first sublayer, which is still in a molten state, forcing the optical feature particles to align along the die texture under pressure. After solidification, a first machine-readable coded pattern containing information such as cable type and production date is formed. After the first sublayer cools and solidifies, a second composite material consisting of 75-95 parts of transparent epoxy resin and 3-15 parts of field-responsive optical material dispersed therein is coated on its surface to form the second sublayer. The second composite material also includes 0.5-3 parts of dispersant. 0.8-3 parts of a second type of nano-reinforcing agent are uniformly mixed in the second sublayer to enhance its conductivity and response speed.

[0036] This invention also discloses a method of using a signal cable, comprising the following steps: Step 1: Using an external reading device to read the static first machine-readable coding pattern composed of optical feature particles arranged in the first sub-layer through the outer protective sleeve 3, the cable's identity information and specification parameters are obtained; Step 2: Apply a detection electrical signal to the signal conductor 11 of the cable core 1, or monitor the dynamic optical signal generated by the second sublayer due to electrical, thermal or pressure excitation using an external reading device under the natural working state of the cable. Step 3: Combining the static first machine-readable encoded pattern with the dynamic optical signal, a comprehensive judgment and identification is made on the authenticity, energized status or overload condition of the cable.

[0037] In the second step, the detection electrical signal applied to the signal conductor 11 is a pulse voltage or a carrier signal of a specific frequency, which excites the field-responsive optical material in the second sublayer to produce a corresponding pulsed or frequency-specific dynamic optical response. This gives the dynamic optical signal a unique "signature," further enhancing the uniqueness and anti-interference capability of the identification.

[0038] This invention introduces materials sensitive to physical fields such as electric fields, temperature, and pressure into the composite functional layer 4, enabling the cable itself to possess "sensing-response" capabilities. When the cable is in different states (such as energized operation, overload heating, or compression), the second sub-layer generates dynamic optical changes in real time (such as color changes or pattern appearance). This dynamic signal is spatially superimposed on the static code of the first sub-layer and linked in time. External reading devices not only need to read the static code but also verify the correctness of the dynamic signal, which constitutes a dual authentication mechanism, greatly raising the anti-counterfeiting threshold. At the same time, the dynamic signal can also intuitively reflect the working status of the cable, realizing the integration of identification and monitoring.

[0039] Example 1

[0040] like Figure 1 As shown, a signal cable includes, from the inside out, a cable core 1, an inner sheath 2, and an outer protective sheath 3. A composite functional layer 4 is provided between the inner sheath 2 and the outer protective sheath 3. The composite functional layer 4 includes a first sub-layer and a second sub-layer distributed radially. The first sublayer is composed of a transparent first composite material in which optical feature particles (high reflectivity glass microspheres) are dispersed, arranged along the cable axis to form a first machine-readable coded pattern; this layer is mainly used to provide static, unalterable basic identity information, equivalent to the cable's "ID card"; The second sublayer is composed of a transparent second composite material in which field-responsive optical material is dispersed. The field-responsive optical material is used to change its optical properties under external physical field excitation to form a dynamic optical signal superimposed on the first machine-readable coded pattern; this layer is equivalent to the "status indicator" of the cable. The outer protective cover 3 shall cover at least the area of ​​the coded pattern with a light-transmitting material to ensure that the optical signal can be effectively read by an external reading device.

[0041] The cable core 1 includes four conductor units, each conductor unit including a wrapping tape 13 and two signal conductors 11 disposed therein, the signal conductors 11 being covered with an insulation layer 12.

[0042] The signal conductor 11 is a solid copper conductor, the insulation layer 12 is a foamed polyethylene insulation layer, the wrapping tape 13 is an aluminum foil longitudinally wrapped shielding tape, the inner sheath 2 is a thin PVC inner sheath, and the outer protective sheath 3 is a semi-transparent PVC sheath.

[0043] The field-responsive optical material is an electrochromic material, using poly(3,4-ethylenedioxythiophene) (PEDOT).

[0044] The external physical field is the electrical signal applied to the signal conductor 11. When current flows through the signal conductor 11, the electric field around it or the generated Joule heating can excite optical changes in the second sublayer.

[0045] The first sublayer also contains dispersed nano-silica, which is used to improve the dimensional stability and scratch resistance of the first sublayer.

[0046] The second sublayer also contains double-walled carbon nanotubes. The uniformly dispersed carbon nanotubes can form a micro-conductive network in the second sublayer. When the cable is energized, this network can assist in the distribution of the electric field or generate a micro-thermal field, thereby more effectively stimulating the uniformly distributed color-changing material to produce a response.

[0047] The first machine-readable coded pattern is a static optical QR code or barcode containing cable identification information and specifications.

[0048] Dynamic optical signals are color changes.

[0049] A method for manufacturing a signal cable includes the following steps: Step 1) Prepare cable core 1; Step 2) Extrude the inner sheath 2 onto the outside of the cable core 1; Step 3) The first composite material is melt-molded onto the outer side of the inner sheath 2, and a first machine-readable coded pattern composed of optical feature particles is simultaneously formed by molding to form the first sublayer; The transparent second composite material is then melted and molded onto the outside of the first sublayer to form the second sublayer; Step 4) Extrude the outer protective sleeve 3 outside the second sublayer.

[0050] In step 3), 88 parts by weight of thermoplastic polyurethane, 5 parts by weight of optical feature particles, 3 parts by weight of the first type of nano-reinforcing agent, and 1 part by weight of silane coupling agent are melt-blended and then extruded onto the outer side of the inner sheath 2. During the extrusion molding process, a die roller with a micron-level uneven structure is used to press the surface of the first sublayer, which is still in a molten state, forcing the optical feature particles to align along the die texture under pressure. After curing, a first machine-readable coded pattern containing information such as cable type and production date is formed. After the first sublayer cools and solidifies, a second composite material consisting of 80 parts transparent epoxy resin and 10 parts field-responsive optical material dispersed therein is coated on its surface to form the second sublayer. The second composite material also includes 2 parts dispersant. Three parts of a second type of nano-reinforcing agent are uniformly mixed in the second sublayer to enhance its conductivity and response speed.

[0051] A method of using a signal cable includes the following steps: Step 1: Using an external reading device to read the static first machine-readable coding pattern composed of optical feature particles arranged in the first sub-layer through the outer protective sleeve 3, the cable's identity information and specification parameters are obtained; Step 2: Apply a detection electrical signal to the signal conductor 11 of the cable core 1, or monitor the dynamic optical signal generated by the second sublayer due to electrical, thermal or pressure excitation using an external reading device under the natural working state of the cable. Step 3: Combining the static first machine-readable encoded pattern with the dynamic optical signal, a comprehensive judgment and identification is made on the authenticity, energized status or overload condition of the cable.

[0052] In the second step, the detection electrical signal applied to the signal conductor 11 is a pulse voltage or a carrier signal of a specific frequency, which excites the field-responsive optical material in the second sublayer to produce a corresponding pulsed or frequency-specific dynamic optical response. This gives the dynamic optical signal a unique "signature," further enhancing the uniqueness and anti-interference capability of the identification.

[0053] Under static conditions, a handheld QR code scanner can be used to clearly read the static QR code in the first sublayer through the outer protective sleeve 3 to obtain the cable identification information.

[0054] Subsequently, a 5V DC voltage is applied to the signal conductor 11. After approximately 2 seconds, the previously transparent second sublayer area visibly turns light blue. At this time, the background of the QR code read by the scanner turns blue, and this change is recognized as a valid dynamic signal of "power-on state". If the scanner cannot read the static QR code, or if the background does not turn blue as preset when reading the static QR code, the system determines that the cable is counterfeit or is in a power-off state.

[0055] Example 2

[0056] The difference between this embodiment and embodiment 1 is that, in order to achieve richer status indication, the second sub-layer of this embodiment also includes three response blocks arranged at intervals along the cable axis: block A, block B and block C. Blocks A, B and C contain different concentrations of field-responsive optical materials to generate stepped dynamic optical signals under external physical field excitation of different intensities.

[0057] Block A contains a low concentration of thermochromic microcapsules (color-changing temperature 45℃), Block B contains a medium concentration of thermochromic microcapsules (color-changing temperature 60℃), and Block C contains a high concentration of thermochromic microcapsules (color-changing temperature 75℃). All thermochromic materials are transparent at room temperature and turn red upon reaching the trigger temperature.

[0058] When the cable load is light and the conductor temperature is below 45°C, all sections are transparent, and a clear static QR code is visible through the outer protective sleeve 3.

[0059] When the cable is overloaded and the conductor temperature reaches 60°C, blocks A and B turn red, while block C remains transparent. At this time, the QR code displays three background colors of "red-red-transparent", indicating that the cable is in a moderate overload state.

[0060] When the cable is severely overloaded and the conductor temperature reaches above 75°C, all three blocks turn red, the QR code background turns completely red, and a strong visual warning signal is emitted.

[0061] This tiered dynamic response provides maintenance personnel with intuitive and quantifiable status indicators, allowing them to make preliminary judgments about the health status of cables without the need for any electronic devices.

[0062] The rest is the same as in Example 1.

[0063] Any parts or structures not specifically described in this invention can be made using existing technologies or products, and will not be elaborated upon here.

[0064] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A signal cable, characterized in that, From the inside out, the cable consists of a cable core, an inner sheath, and an outer protective sheath. A composite functional layer is provided between the inner sheath and the outer protective sheath. The composite functional layer includes at least a first sub-layer and a second sub-layer distributed radially. The first sublayer is composed of a transparent or translucent first composite material, wherein optical feature particles are dispersed therein, arranged along the cable axis to form a first machine-readable coded pattern; The second sublayer is composed of a transparent second composite material in which field-responsive optical material is dispersed, the field-responsive optical material being used to change its optical properties under external physical field excitation to form a dynamic optical signal superimposed on the first machine-readable coded pattern; The outer protective cover shall at least cover the area of ​​the coded pattern with a light-transmitting material.

2. The signal cable according to claim 1, characterized in that, The field-responsive optical material is one or more of electrochromic materials, thermochromic materials, and piezochromic materials, and the external physical field is an electrical signal applied to the signal conductor of the cable core, a temperature change of the cable body, or external mechanical stress.

3. A signal cable according to claim 1, characterized in that, The first sublayer also contains a first type of nano-reinforcing agent, and the second sublayer also contains a second type of nano-reinforcing agent.

4. A signal cable according to claim 3, characterized in that, The first type of nano-reinforcing agent is a rigid nanoparticle, and the second type of nano-reinforcing agent is a conductive nanomaterial.

5. A signal cable according to claim 4, characterized in that, The rigid nanoparticles are nano-silica, and the conductive nanomaterials are single-walled or double-walled carbon nanotubes.

6. A signal cable according to claim 1, characterized in that, The second sublayer also includes multiple response blocks spaced apart along the cable axis. Each response block contains different types or concentrations of field-responsive optical materials to generate stepped dynamic optical signals under external physical field excitation of different intensities.

7. A signal cable according to claim 1, characterized in that, The first machine-readable encoded pattern is a static optical QR code or barcode containing cable identification information and specifications.

8. A signal cable according to claim 1, characterized in that, The dynamic optical signal is a change in color, a change in transparency, or the appearance and disappearance of a pattern.

9. A method for manufacturing a signal cable according to any one of claims 1-8, characterized in that, Includes the following steps: Step 1): Prepare the cable core; Step 2) Extruding the inner sheath onto the outside of the cable core; Step 3) Melt and mold a transparent or translucent first composite material onto the outer side of the inner sheath, and simultaneously form a first machine-readable coded pattern composed of optical feature particles by molding or laser etching to form the first sublayer; The transparent second composite material is then melted and molded onto the outside of the first sublayer to form the second sublayer; Step 4) Extrude an outer protective sleeve outside the second sublayer.

10. A method of using a signal cable according to any one of claims 1-8, characterized in that, Includes the following steps: Step 1: Using an external reading device to read the static first machine-readable code pattern composed of optical feature particles arranged in the first sub-layer through the outer protective sleeve, the cable's identity information and specification parameters are obtained; Step 2: Apply a detection electrical signal to the signal conductor of the cable core, or, under the natural working condition of the cable, use the external reading device to monitor the dynamic optical signal generated by the second sublayer due to electrical, thermal, or pressure excitation; Step 3: Combining the static first machine-readable encoded pattern with the dynamic optical signal, a comprehensive judgment and identification is made on the authenticity, energized status or overload condition of the cable.

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