A method for optimizing the UV glue penetration curing process of a large-current silica gel braided charging cord

Abstract

This invention discloses an optimized method for the UV adhesive penetration and curing process of high-current silicone braided charging cables. It aims to solve the problems of insufficient UV adhesive penetration depth and uneven distribution leading to poor flexibility and low abrasion resistance in existing technologies. The method uses the pitch density of the braided structure as the core control parameter to construct a fully adaptive process. Based on a resistance-temperature relationship model, static electricity elimination is triggered; the pressure recovery rate matches the braiding tightness to avoid adhesive surface accumulation; the conical mold parameters adjust the shear stress according to the fiber gap ratio to ensure uniform adhesive distribution; the curing energy formula compensates for the influence of linear speed and braiding density, achieving gradient curing of the surface and inner layers; the preset bending radius matches the actual bending characteristics in use; and the heat treatment parameters are optimized for stress elimination based on the pitch density. Through this process, the adhesive penetration depth is improved, enabling stable long-distance high-current transmission while meeting the abrasion resistance requirements for denim fabric's fuzzing length.

Description

Technical Field

[0001] This invention relates to the field of UV adhesive penetration curing technology for charging cables, and in particular to an optimized method for UV adhesive penetration curing process of high-current silicone braided charging cables. Background Technology

[0002] With the rapid popularization of mobile electronic devices and the widespread application of fast charging technology, the market demand for Type-C charging cables that support high current transmission is increasing. In order to meet the voltage drop requirements for long-distance transmission, existing charging cables generally adopt a multi-strand thickened conductor structure, which increases the overall rigidity of the cable and makes it feel stiff. At the same time, in order to improve flexibility and wear resistance, the industry generally adopts a silicone braided outer sheath structure, but this structure has certain technical bottlenecks in the actual manufacturing process.

[0003] Currently, most mainstream charging cable manufacturing processes employ an extrusion-spraying-curing process. However, the UV adhesive spraying and curing stage suffers from issues such as insufficient adhesive penetration depth and uneven distribution. When using atmospheric pressure spraying, the adhesive struggles to penetrate the dense braided layer, resulting in gaps between the braided layer and the inner core. This leads to slippage and wear during repeated bending or friction, accelerating core breakage. To ensure surface smoothness, the amount of adhesive often needs to be increased, causing the cable to harden overall after curing and lose its flexibility. Furthermore, the curing process typically uses fixed-power UV light irradiation, which cannot adapt to changes in line speed, easily causing over-curing of the surface layer while the inner layer remains uncured, resulting in a core-sheath effect.

[0004] While some existing patents mention vacuum infiltration or segmented curing, none of them use the physical characteristics of the braided structure as a core control parameter. Instead, they employ fixed parameters or simple proportional adjustments, failing to resolve the contradiction between adhesive penetration and flexibility in high-density braided structures. These technical deficiencies make it difficult for existing charging cables to simultaneously achieve stable 7A high-current transmission and flexibility / wear resistance at a length of 1.8m, failing to meet consumers' core demands for long-distance transmission without overheating and repeated bending without wear. The industry urgently needs an innovative manufacturing method that can deeply couple the physical characteristics and process parameters of the braided structure of the cable, fundamentally resolving the technical paradox of requiring thick conductors for high-current transmission and dense braiding for flexibility and wear resistance. Summary of the Invention

[0005] The purpose of this invention is to provide an optimized method for the UV adhesive penetration and curing process of high-current silicone braided charging cables.

[0006] The problem to be solved by this invention is to address the issues of poor flexibility and low wear resistance caused by insufficient penetration depth and uneven distribution of adhesive in the traditional UV adhesive penetration curing process for charging cables.

[0007] An optimized method for UV adhesive penetration curing of high-current silicone braided charging cables, the technical solution of which is as follows: S1: Preheating and static elimination treatment: The temperature of the woven semi-finished yarn is adjusted by a preheating device. The semi-finished yarn includes an internal conductor and an outer braided structure. At the same time, a static elimination device is used to neutralize the static electricity on the surface of the yarn to eliminate surface static electricity and optimize the adhesive adhesion conditions. S2: Vacuum negative pressure assisted infiltration treatment: The preheated wire is placed into a closed infiltration reaction chamber. UV adhesive is evenly sprayed onto the surface of the wire through a high-pressure atomizing nozzle. The vacuum system is activated to create a negative pressure environment inside the chamber. Based on the air pressure difference, the UV adhesive is driven to penetrate into the microporous structure of the braided yarn, realizing the active penetration of the adhesive into the braided layer. S3: Fluid shear-assisted molding process: The wire is passed through a conical mold made of elastic material, the inner diameter of which is smaller than the diameter of the wire. The wire passes through the mold at a continuous transmission speed, and shear stress is generated through the mold, which breaks the surface tension of the UV adhesive and causes the adhesive to flow into the interior of the wire, forming a uniform adhesive layer distribution. S4: Segmented gradient curing treatment based on linear speed and yarn density: The output intensity of the UV light source is adjusted according to the transmission speed of the yarn, and a segmented curing strategy is adopted. The first segment uses a lower energy intensity for initial surface curing, and the second segment uses a higher energy intensity for deep internal curing, so as to achieve gradient curing of the adhesive. S5: Curing in bending state: The wire is introduced into the UV curing area through the bending guide device, so that the wire maintains the preset bending radius during the curing process. At the same time, segmented gradient curing is performed so that the adhesive can be cured in the bending state to match the bending characteristics of the charging cable in actual use. S6: Post-heat treatment and stress relief: After UV curing, the wire is briefly heated by an infrared heat treatment device to eliminate the internal stress generated during the curing process and improve the stability of the wire structure.

[0008] Furthermore, in step S1, the temperature of the braided semi-finished wire is adjusted by a preheating device, and the surface of the wire is neutralized by an electrostatic elimination device, including: The preheating device integrates a temperature monitoring module and a static electricity elimination module; During the preheating process, the temperature monitoring module collects surface temperature data of the wire and calculates the surface resistance value of the wire based on the resistance-temperature relationship model constructed based on the material properties of the outer braided structure of the charging wire. The resistance-temperature relationship model is as follows: ,in, This represents the surface resistivity at temperature T. Reference temperature The initial resistance value is given, k1 is the material property coefficient determined experimentally, and T is the current temperature. When the surface resistance of the wire drops to a preset critical threshold, the static elimination module is activated to perform directional static neutralization treatment on the wire surface, thereby eliminating surface static electricity and optimizing the adhesion conditions of the subsequent UV adhesive. The critical threshold is preset based on the typical resistivity range of the outer braided structure of the charging cable, ensuring that static elimination is performed only when the surface static elimination efficiency is highest, thus avoiding the problem of low static elimination efficiency caused by the independent execution of traditional preheating and static elimination processes. The resistance-temperature dynamic relationship model is pre-calibrated using the material physical properties of the charging cable braided structure and triggered by the physical correlation between the material properties of the cable itself and the preheating temperature.

[0009] Furthermore, in step S2, the vacuum system is activated to create a negative pressure environment within the cavity, and the UV adhesive is driven to penetrate the microporous structure of the yarn based on the pressure difference, including: Start the vacuum system to rapidly reduce the pressure inside the chamber to the preset negative pressure value and maintain this negative pressure state for a period of time. Then control the pressure inside the chamber to gradually rise back to normal pressure at a constant rate. The constant rate v1 is adjusted according to the tightness of the outer layer of the yarn braiding structure. The adjustment formula is as follows: ,in This is the vacuum process constant, which is experimentally calibrated to ensure that pressure changes match the permeation process. The pitch density; When the yarn structure is dense, the pressure recovery rate decreases accordingly, ensuring that the UV adhesive penetration process in the yarn microporous structure forms a dynamic balance with the pressure change, avoiding the rapid accumulation of adhesive on the surface of the braided layer to form an isolation layer, while promoting the uniform penetration of adhesive into the conductor area inside the wire. The degree of tightness is determined based on the pitch density of the yarn structure. The process parameters are adjusted through a preset physical characteristic parameter library to form a dedicated penetration process for the yarn structure of charging cables.

[0010] Furthermore, in step S3, the inner diameter of the mold is smaller than the diameter of the wire, and the wire passes through the mold at a continuous transmission speed, generating shear stress through the mold to break the surface tension of the UV adhesive, including: The cone angle and elastic modulus of the cone mold are preset based on the fiber gap ratio of the outer layer of the yarn braiding structure, where the fiber gap ratio refers to the proportion of the average gap space between fibers in the braiding structure to the overall structural volume. When the wire passes through the mold at a continuous transmission speed, the elastic characteristics of the mold and the flow characteristics of the UV adhesive on the surface of the wire are coupled together, generating shear stress. The magnitude of the shear stress is adapted to the fiber gap ratio. That is, when the fiber gap ratio is high, the shear stress automatically decreases to prevent excessive accumulation of adhesive on the surface, and when the fiber gap ratio is low, the shear stress automatically increases to promote the penetration of adhesive into the conductor region inside the wire. This adaptive shear control, based on the physical properties of the yarn weaving structure, enables the uniform distribution of adhesive within the micropores of the yarn weaving.

[0011] Furthermore, in step S4, the output intensity of the UV light source is adjusted according to the transmission speed of the wire, and a segmented curing strategy is adopted, including: Monitor the transmission speed and braiding density of the wire, and adjust the output intensity of the UV light source according to the preset curing energy calculation formula to achieve segmented gradient curing; The formula for calculating the curing energy is as follows: ,in K represents the required curing energy density, and K is an empirical coefficient for the material, a pre-calibrated constant based on the silicone / polyester material system with the braided outer layer structure of the charging cable. For cable transmission speed, The viscosity of the UV adhesive; The material empirical coefficient K is predetermined by the typical physical characteristics of the outer braided structure of the charging cable, without relying on real-time measurement, and is only used as an inherent property parameter of the material system. When the wire transmission speed When increased, curing energy The pitch density is increased accordingly to compensate for the shortened UV light exposure time caused by the increased linear speed; when the yarn pitch density is increased... When the curing energy increases, The corresponding increase is to overcome the blocking effect of high-density yarn on UV light; The segmented gradient curing strategy includes: the first curing stage employs... The surface is initially cured using 70% of the energy value, and the second curing stage uses... It uses 100% energy value for deep internal curing, ensuring that the adhesive forms an elastic film on the surface while achieving complete cross-linking inside.

[0012] Furthermore, in step S5, the wire is introduced into the UV curing area via a bending guide device, so that the wire maintains a preset bending radius during the curing process, while performing segmented gradient curing treatment, including: The preset bending radius of the bending guide device is set based on the yarn pitch density, and the formula for calculating the preset bending radius is as follows: ,in To preset the bending radius, The bending empirical coefficient is a pre-calibrated constant for the silicone / polyester material system of the outer braided structure of the charging cable; The bending guide device is based on calculations. Adjust the bending radius to maintain the preset bending radius of the wire during the curing process. At the same time, perform segmented gradient curing to ensure that the adhesive cures evenly in the bent state and avoid uneven curing or wire damage caused by mismatched bending radii.

[0013] Furthermore, in step S6, the wire is briefly heated using an infrared heat treatment device to eliminate internal stress generated during the curing process, including: The heating temperature and heating time of the infrared heat treatment device are adjusted according to the pitch density of the outer layer of the wire braided structure, wherein the pitch density is the average spacing parameter between adjacent fibers in the braided structure. When the pitch density is high, the heating temperature is reduced to the preset low temperature range, and the heating time is extended to the preset long time range; when the pitch density is low, the heating temperature is increased to the preset high temperature range, and the heating time is shortened to the preset short time range. The adjustment mechanism is implemented through a pre-built heat treatment parameter library, which is calibrated based on the typical physical characteristics of the outer layer of the charging cable's braided structure, and the heat treatment parameters are matched with the inherent characteristics of the braided structure.

[0014] The beneficial effects of this invention are as follows: By constructing a closed-loop adaptive control system for the entire process driven by the physical characteristics of the outer braided structure of the charging cable, the six major steps of preheating, penetration, shearing and molding, gradient curing, bending curing and post-heat treatment are deeply coupled to form an inseparable process logic chain. This enables the simultaneous realization of high current transmission, flexible feel and ultra-long wear resistance over long distances, thus solving a long-standing technical contradiction in the industry.

[0015] Abandoning the conventional approach of fixing parameters in general wire manufacturing, we take the inherent physical properties of the braided structure, including pitch density, fiber gap ratio, and resistance-temperature characteristics, as the core input for process control, so that the parameters of each link match the microstructural characteristics of the wire.

[0016] The resistance-temperature relationship model triggers electrostatic discharge (ESD) by leveraging the inherent material properties of the wire, avoiding ESD failures caused by traditional independent processes. The pressure recovery rate formula adjusts the pressure gradient based on pitch density, ensuring that adhesive slowly penetrates the micropores under high-density braiding without forming a surface isolation layer. The denominator of the curing energy formula physically compensates for the UV light blocking effect of high-density braiding, avoiding the problems of uncured inner layers or over-cured surface layers caused by traditional fixed-energy curing. The bending radius formula binds the wire's bending characteristics to the braiding stiffness depth, ensuring that the bending radius during the curing process precisely matches the actual application scenario. The heat treatment parameter library adjusts temperature and time based on pitch density, eliminating uneven internal stress caused by differences in braiding tightness.

[0017] This process control based on pitch density allows for a stable increase in the penetration depth of the adhesive into the microporous structure of the yarn. At the same time, gradient curing ensures the formation of an elastic film on the surface and complete cross-linking of the inner layer, avoiding the contradiction of a hard outer layer and a soft inner layer in traditional processes. Attached Figure Description

[0018] Figure 1 A flowchart illustrating an optimized UV adhesive penetration curing process for a high-current silicone braided charging cable. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] In order to achieve the above objectives, Figure 1 A flowchart of the optimized UV adhesive penetration curing process for a high-current silicone braided charging cable is provided.

[0021] Furthermore, the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this article, unless otherwise specified, generally indicates that the preceding and following related objects have an "or" relationship.

[0022] Example 1 An optimized method for UV adhesive penetration curing of high-current silicone braided charging cables, the technical solution of which is as follows: S1: Preheating and static elimination treatment: The temperature of the woven semi-finished yarn is adjusted by a preheating device. The semi-finished yarn includes an internal conductor and an outer braided structure. At the same time, a static elimination device is used to neutralize the static electricity on the surface of the yarn to eliminate surface static electricity and optimize the adhesive adhesion conditions. S2: Vacuum negative pressure assisted infiltration treatment: The preheated wire is placed into a closed infiltration reaction chamber. UV adhesive is evenly sprayed onto the surface of the wire through a high-pressure atomizing nozzle. The vacuum system is activated to create a negative pressure environment inside the chamber. Based on the air pressure difference, the UV adhesive is driven to penetrate into the microporous structure of the braided yarn, realizing the active penetration of the adhesive into the braided layer. S3: Fluid shear-assisted molding process: The preheated wire is passed through a conical mold made of elastic material. The inner diameter of the mold is smaller than the diameter of the wire. The wire passes through the mold at a continuous transmission speed. Shear stress is generated through the mold, which breaks the surface tension of the UV adhesive and causes the adhesive to flow into the interior of the wire, forming a uniform adhesive layer distribution. S4: Segmented gradient curing treatment based on linear speed and yarn density: The output intensity of the UV light source is adjusted according to the transmission speed of the yarn, and a segmented curing strategy is adopted. The first segment uses a lower energy intensity for initial surface curing, and the second segment uses a higher energy intensity for deep internal curing, so as to achieve gradient curing of the adhesive. S5: Curing in bending state: The wire is introduced into the UV curing area through the bending guide device, so that the wire maintains the preset bending radius during the curing process. At the same time, segmented gradient curing is performed so that the adhesive can be cured in the bending state to match the bending characteristics of the charging cable in actual use. S6: Post-heat treatment and stress relief: After UV curing, the wire is briefly heated by an infrared heat treatment device to eliminate the internal stress generated during the curing process and improve the stability of the wire structure.

[0023] Furthermore, in step S1, the temperature of the braided semi-finished wire is adjusted by a preheating device, and the surface of the wire is neutralized by an electrostatic elimination device, including: The preheating device integrates a temperature monitoring module and a static electricity elimination module; During the preheating process, the temperature monitoring module collects surface temperature data of the wire and calculates the surface resistance value of the wire based on the resistance-temperature relationship model constructed based on the material properties of the outer braided structure of the charging cable.

[0024] Ten typical silicone / polyester braided yarn samples were selected, and their initial resistance values ​​were measured under a constant temperature environment of 25℃±2℃. The samples were placed in a temperature-controlled environment, ranging from 50℃ to 120℃, with 10℃ intervals. The resistance value of each group of samples was measured after stabilizing at each temperature point for 10 minutes. Based on the measurement data, an exponential decay function was used to fit the relationship. Where k1 is the material property coefficient determined experimentally, T is the current temperature, and cross-validation is used to ensure that the model prediction error is ≤5%, with 80% of the data used for modeling and 20% used for validation.

[0025] When the surface resistance of the wire drops to a preset critical threshold, the static elimination module is activated to perform directional static neutralization treatment on the wire surface, thereby eliminating surface static electricity and optimizing the adhesion conditions of the subsequent UV adhesive. The critical threshold is preset based on the typical resistivity range of the outer braided structure of the charging cable, and is 0.7 times the lowest resistance value predicted by the model at 120℃, derived from experimental data on static elimination efficiency; the typical resistivity range is set to 10 based on industry standard data for silicone / polyester braided structures. 3 -10 6 ; The surface charge density is highest and the electrostatic elimination efficiency reaches its peak when the resistance value is between the lowest resistance value predicted by the model and the critical threshold. When the threshold is too low, electrostatic elimination will be delayed, and when the threshold is too high, the electrostatic elimination efficiency will decrease. This ensures that static elimination is performed only when the surface static elimination efficiency is highest, avoiding the problem of low static elimination efficiency caused by the traditional separate execution of preheating and static elimination processes.

[0026] The resistance-temperature dynamic relationship model is pre-calibrated using the material physical properties of the charging cable braided structure. It is triggered by the physical correlation between the material properties of the cable itself and the preheating temperature, avoiding the limitations of relying on a fixed temperature threshold in traditional methods. When the silicone content is high, the k1 value increases by about 0.03, and the resistance decreases faster. When the polyester content is high, the k1 value decreases by about 0.01, and the resistance decreases slower.

[0027] Furthermore, in step S2, the vacuum system is activated to create a negative pressure environment within the cavity, and the UV adhesive is driven to penetrate the microporous structure of the yarn based on the pressure difference, including: The vacuum system is activated to rapidly reduce the pressure inside the cavity to the preset negative pressure value and maintain this negative pressure state for a period of time. Then, the pressure inside the cavity is controlled to gradually rise back to normal pressure at a constant rate.

[0028] The constant rate v1 is adjusted according to the tightness of the outer layer of the yarn braiding structure. The adjustment formula is as follows: ,in This is the vacuum process constant, which is experimentally calibrated to ensure that pressure changes match the permeation process. The pitch density; When the yarn structure is dense, the pressure recovery rate decreases accordingly, ensuring that the penetration process of UV adhesive in the microporous structure of the yarn is in dynamic balance with the pressure change, avoiding the rapid accumulation of adhesive on the surface of the braided layer to form an isolation layer, while promoting the uniform penetration of adhesive into the conductor area inside the wire. The table above shows the silicone / polyester braided structure based on 100 sets of actual production tests.

[0029] The degree of tightness is determined based on the pitch density of the yarn structure. The smaller the pitch density, the tighter the fiber arrangement. A pitch density of 1.0 mm / turn indicates a tight structure, and a pitch density of 3.0 mm / turn indicates a loose structure. By adjusting the process parameters through a preset library of physical characteristic parameters, a dedicated penetration process is formed for the braided structure of charging cables.

[0030] Furthermore, in step S3, the inner diameter of the mold is smaller than the diameter of the wire, and the wire passes through the mold at a continuous transmission speed, generating shear stress through the mold to break the surface tension of the UV adhesive, including: The cone angle and elastic modulus of the cone mold are preset based on the fiber gap ratio of the outer layer of the yarn braiding structure, where the fiber gap ratio refers to the proportion of the average gap space between fibers in the braiding structure to the overall structural volume.

[0031] Randomly cut 10mm×10mm samples from the outer braided structure of the wire, with at least 3 samples per batch; take cross-sectional images of the samples using a 50x optical microscope with a resolution of ≥1024×1024 pixels; identify fiber areas with gray values ​​<100 using image processing software, and calculate the area ratio of blank areas as the number of pixels in the gap area divided by the total number of pixels. Based on 100 sets of historical production data, typical gap rate ranges were established: low gap rate is when the blank area accounts for less than 20%, medium gap rate is when the blank area accounts for 20%-30%, and high gap rate is when the blank area accounts for more than 30%.

[0032] When the wire passes through the mold at a continuous transmission speed, the elastic characteristics of the mold and the flow characteristics of the UV adhesive on the surface of the wire are coupled together, generating shear stress.

[0033] The magnitude of the shear stress is adapted to the fiber gap ratio; when the fiber gap ratio is high (greater than 30%), the small cone angle is 5° + low elastic modulus is 10 MPa, and the shear stress automatically decreases to prevent excessive accumulation of adhesive on the surface; when the fiber gap ratio is low (<20%), the small cone angle is 10° + low elastic modulus is 50 MPa, and the shear stress automatically increases to promote the penetration of adhesive into the conductor area inside the wire. This adaptive shear control, based on the physical properties of the yarn weaving structure, enables the uniform distribution of adhesive within the micropores of the yarn weaving. The table above shows a typical parameter matching example.

[0034] Furthermore, in step S4, the output intensity of the UV light source is adjusted according to the transmission speed of the wire, and a segmented curing strategy is adopted, including: The transmission speed and yarn density of the wire are monitored, and the output intensity of the UV light source is adjusted according to the preset curing energy calculation formula to achieve segmented gradient curing.

[0035] The formula for calculating the curing energy is as follows: ,in Where is the required curing energy density, is the energy required for UV irradiation per unit area, and K is an empirical coefficient for the material, a pre-calibrated constant based on the silicone / polyester material system with the braided outer layer structure of the charging cable. For cable transmission speed, The viscosity of the UV adhesive; and The product of these two values ​​reflects the balance between glue flow and UV exposure time. The denominator design matches the square root attenuation law of UV light penetration, and the blocking effect of high-density yarn on UV light increases in an increasing order of square root.

[0036] The material empirical coefficient K is predetermined by the typical physical characteristics of the outer braided structure of the charging cable, without relying on real-time measurement, and is only used as an inherent property parameter of the material system. When the wire transmission speed When increased, curing energy The pitch density is increased accordingly to compensate for the shortened UV light exposure time caused by the increased linear speed; when the yarn pitch density is increased... When the curing energy increases, The corresponding increase is to overcome the blocking effect of high-density yarn on UV light.

[0037] The segmented gradient curing strategy includes: the first curing stage employs... The surface is initially cured at 70% energy value, allowing only an elastic film to form on the surface UV adhesive, preventing rapid curing that would prevent the internal adhesive from penetrating; the second curing stage uses... The 100% energy value is used for deep internal curing, ensuring that while the adhesive forms an elastic film on the surface, it provides enough energy to fully cross-link the adhesive inside the braided layer, ensuring that the conductor area is fully cured.

[0038] when It is 15. It is 1.2. When K is 50 and K is 1, for The energy of the first segment is 684 × 70% = 479.

[0039] Furthermore, in step S5, the wire is introduced into the UV curing area via a bending guide device, so that the wire maintains a preset bending radius during the curing process, while performing segmented gradient curing treatment, including: The preset bending radius of the bending guide device is set based on the yarn pitch density, and the formula for calculating the preset bending radius is as follows: ,in To preset the bending radius, The bending empirical coefficient is a pre-calibrated constant for the silicone / polyester material system of the outer braided structure of the charging cable; Bending stress has a square root relationship with the geometric properties of the yarn structure. To increase the bending radius (for looser structures), it is necessary to increase it proportionally to the square root of the radius to avoid damage to the wire due to an excessively small bending radius.

[0040] The bending guide device is based on calculations. Adjust the bending radius to maintain the preset bending radius of the wire during the curing process. At the same time, perform segmented gradient curing to ensure that the adhesive cures evenly in the bent state and avoid uneven curing or wire damage caused by mismatched bending radii.

[0041] Typical groups were divided according to the silicone / polyester ratio, including 40% / 60%, 50% / 50%, and 60% / 40%. Ten test wires were made for each group, and the uniformity of the adhesive at different bending radii was measured using a bending tester. The target was that the standard deviation of the adhesive layer thickness should be ≤0.05mm. Regression analysis was used to determine... ,Will It is associated with the mixing ratio and stored in the preset parameter library. The table above shows a typical parameter matching example.

[0042] Furthermore, in step S6, the wire is briefly heated using an infrared heat treatment device to eliminate internal stress generated during the curing process, including: The heating temperature and heating time of the infrared heat treatment device are adjusted according to the pitch density of the outer layer of the yarn structure, where the pitch density is the average spacing parameter between adjacent fibers in the yarn structure; when the structure is loose, heat conduction is fast, and the heating time needs to be extended to release stress evenly; when the structure is tight, heat conduction is slow, and the time needs to be shortened to avoid heat damage.

[0043] When the pitch density is high, the structure is loose and heat dissipation is fast, the heating temperature is correspondingly reduced to the preset low temperature range, and the heating time is correspondingly extended to the preset long time range; when the pitch density is low, the structure is tight and heat conduction is slow, the heating temperature is correspondingly increased to the preset high temperature range, and the heating time is correspondingly shortened to the preset short time range.

[0044] The adjustment mechanism is implemented through a pre-built heat treatment parameter library, which is calibrated based on the typical physical characteristics of the outer layer of the charging cable's braided structure, and the heat treatment parameters are matched with the inherent characteristics of the braided structure.

[0045] The materials were divided into groups based on typical silicone / polyester ratios, including 40% / 60%, 50% / 50%, and 60% / 40%. Ten test wires were made for each group of materials and heat-treated under different combinations of heating temperature and heating time. The internal stress value after curing was measured using a stress detector. The target internal stress was ≤5 MPa. The optimal parameter combination was determined. The yarn pitch density was correlated with the corresponding parameters and stored in a preset heat treatment parameter library. The table above shows a typical parameter matching example.

[0046] Example 2 This embodiment focuses on a specific implementation of a yarn-woven structure with a silicone / polyester ratio of 55% / 45% to verify the compatibility of process parameters and practical application effects of the present invention under different material ratios. This example supplements the complete implementation process of fiber gap rate measurement and mold parameter setting in step S3.

[0047] Preparation of yarn braiding structure samples: Select a yarn braiding structure sample of the outer layer of the charging cable with a silicone / polyester ratio of 55% / 45%, and randomly cut 3 samples of 10mm×10mm each. There should be at least 3 samples in each batch to ensure the representativeness of the samples.

[0048] Cross-sectional images of the samples were captured using a 50x optical microscope with a resolution of 1024×1024 pixels. Fiber regions with grayscale values ​​<100 were identified using ImageJ image processing software, and the gap ratio was calculated. The gap ratio of sample 1 was 28.5%, that of sample 2 was 27.8%, and that of sample 1 was 28.2%, with an average gap ratio of 28.2%. Based on the gap ratio range established in Example 1, this sample was determined to belong to a medium gap ratio structure.

[0049] According to the parameter matching table in Example 1, a medium clearance ratio corresponds to a cone angle of 8° and an elastic modulus of 30 MPa, which are set as the parameters of the cone mold.

[0050] The preheated wire is passed through the mold at a continuous transmission speed of 20. The shear stress generated by the mold is 240, which is the product of the cone angle and the elastic modulus. The measured standard deviation of the adhesive layer thickness is 0.04 mm, which is better than the 0.08 mm of the traditional process.

[0051] The adhesive is evenly distributed in the micropores of the yarn, with no surface adhesive accumulation. This is consistent with the effect achieved with the same parameters in Example 1, verifying the reliability of the parameter library.

[0052] For the braided structure measured in S3, the gap ratio is 28.2%, the braided pitch density is 2.3, the material empirical coefficient is 1.0, the UV adhesive viscosity is 55, and the wire transmission speed is 20. Curing energy is calculated as follows The curing energy of the first stage is 725.6 × 70% = 507.9, forming an elastic film on the surface with a thickness of 0.05 mm, and achieving complete cross-linking inside.

[0053] According to the parameter library of Example 1 S5, the bending empirical coefficient corresponding to the silicone / polyester ratio of 55% / 45% is 2.7, and the preset bending radius is 2.7×1.516=4.1 mm; The wire was cured at a bending radius of 4.1 mm, with a standard deviation of adhesive layer thickness of 0.035 mm and a target of ≤0.05 mm.

[0054] The yarn pitch density is 2.3, which is considered medium density. According to the parameter library of Example 1 S6, the corresponding heating temperature is 90℃, the heating time is 22S, and the internal stress after heat treatment is 4.2 MPa, with a target of ≤5 MPa.

[0055] By implementing the specific ratio of 55% / 45%, the matching of process parameters of the present invention when the silica content is higher than 50% was verified, which made up for the limitation of Example 1 which only provided 40% / 60%, 50% / 50%, and 60% / 40%.

[0056] All formulas in this invention are dimensionless and calculated by taking their numerical values. Dimensionlessness can be achieved through various methods such as standardization, which will not be elaborated here. The formulas are derived from software simulations using a large amount of collected data to obtain the most recent real-world results. The preset parameters in the formulas can be set by those skilled in the art according to the actual situation.

[0057] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An optimized method for UV adhesive penetration and curing process of high-current silicone braided charging cables, characterized in that, include: S1: Preheating and static elimination treatment: The woven semi-finished yarn is preheated by a preheating device and the surface of the yarn is neutralized by a static elimination device. The semi-finished yarn includes an internal conductor and an outer braided structure. S2: Vacuum negative pressure assisted infiltration treatment: The preheated wire is placed into a closed infiltration reaction chamber, and UV adhesive is evenly sprayed onto the surface of the wire through a high-pressure atomizing nozzle. The vacuum system is activated to create a negative pressure environment in the chamber, and the UV adhesive is driven to penetrate into the microporous structure of the yarn based on the air pressure difference. S3: Fluid shear-assisted molding process: The wire is passed through a conical mold, the inner diameter of which is smaller than the diameter of the wire. The wire passes through the mold at a continuous transmission speed, and the mold generates shear stress, which breaks the surface tension of the UV adhesive and promotes the adhesive to flow into the interior of the wire, forming a uniform adhesive layer distribution. S4: Segmented gradient curing treatment based on linear speed and yarn density: The output intensity of the UV light source is adjusted according to the transmission speed of the yarn, and a segmented curing strategy is adopted for curing. S5: Curing in a Bending State: The wire is introduced into the UV curing area through a bending guide device, so that the wire maintains a preset bending radius during the curing process, and a segmented gradient curing process is performed so that the adhesive can be cured in a bending state. S6: Post-heat treatment and stress relief: After UV curing, the wire is briefly heated by an infrared heat treatment device to eliminate the internal stress generated during the curing process.

2. The optimized method for UV adhesive penetration and curing of high-current silicone braided charging cables as described in claim 1, characterized in that, In step S1, the braided semi-finished wire is preheated using a preheating device, and the surface of the wire is neutralized using an electrostatic elimination device, including: The preheating device is equipped with a temperature monitoring module and a static electricity elimination module; During the preheating process, the temperature monitoring module collects surface temperature data of the wire, constructs a resistance-temperature relationship model based on the material properties of the braided structure, and calculates the surface resistance value of the wire. The resistance-temperature relationship model is as follows: ,in, This represents the surface resistivity at temperature T. Reference temperature The initial resistance value is given, k1 is the material property coefficient determined experimentally, and T is the current temperature. When the surface resistance of the wire drops to a preset critical threshold, the static elimination module is activated to neutralize the static electricity on the wire surface. The critical threshold is preset based on the typical resistivity range of the yarn structure, and the resistance-temperature relationship model is pre-calibrated based on the material physical properties of the yarn structure.

3. The optimized method for UV adhesive penetration and curing of high-current silicone braided charging cables as described in claim 1, characterized in that, The vacuum system activated in step S2 creates a negative pressure environment within the cavity, driving the UV adhesive to penetrate the microporous structure of the yarn based on the pressure difference. This includes: The vacuum system is activated to reduce the pressure inside the chamber to a preset negative pressure value and maintain it for a predetermined time. Then, the pressure inside the chamber is controlled to rise back to normal pressure at a constant rate. The constant rate is adjusted according to the tightness of the outer layer of the yarn braiding structure. The constant rate is inversely proportional to the tightness, and the adjustment formula is as follows: ,in This is the vacuum process constant. The pitch density; The degree of tightness is determined based on the pitch density of the yarn structure. The process parameters can be adjusted through a preset library of physical property parameters.

4. The optimized method for UV adhesive penetration and curing of high-current silicone braided charging cables as described in claim 1, characterized in that, In S3, the inner diameter of the mold is smaller than the diameter of the wire. The wire passes through the mold at a continuous transmission speed, generating shear stress through the mold, which breaks the surface tension of the UV adhesive, including: The cone angle and elastic modulus of the cone mold are preset based on the fiber gap ratio of the outer layer of the yarn braiding structure, where the fiber gap ratio refers to the proportion of the average gap space between fibers in the braiding structure to the overall structural volume. When the wire passes through the mold at a continuous transmission speed, the elastic characteristics of the mold and the flow characteristics of the UV adhesive on the surface of the wire are coupled together, generating shear stress. The magnitude of the shear stress is inversely proportional to the magnitude of the fiber gap ratio.

5. The optimized method for UV adhesive penetration and curing of high-current silicone braided charging cables as described in claim 1, characterized in that, In step S4, the output intensity of the UV light source is adjusted according to the transmission speed of the wire, and a segmented curing strategy is used for curing, including: Monitor the transmission speed and braiding density of the wire, and adjust the output intensity of the UV light source according to the preset curing energy calculation formula; The formula for calculating the curing energy is as follows: ,in K represents the required curing energy density, and K is an empirical coefficient for the material, a pre-calibrated constant based on the silicone / polyester material system with the braided outer layer structure of the charging cable. For cable transmission speed, The viscosity of the UV adhesive. The pitch density of the yarn; The material empirical coefficient K is predetermined by the typical physical characteristics of the outer braided structure of the charging cable, without relying on real-time measurement, and is only used as an inherent property parameter of the material system. The wire transmission speed is directly proportional to the curing energy; the yarn pitch density is directly proportional to the curing energy. The segmented gradient curing strategy includes: the first curing stage employs... The surface is initially cured using 70% of the energy value, and the second curing stage uses... It uses 100% of its energy value for deep internal curing.

6. The optimized method for UV adhesive penetration and curing of high-current silicone braided charging cables as described in claim 1, characterized in that, In step S5, the wire is introduced into the UV curing area via a bending guide device, so that the wire maintains a preset bending radius during the curing process, and a segmented gradient curing process is performed, including: The preset bending radius of the bending guide device is set based on the yarn pitch density, and the formula for calculating the preset bending radius is as follows: ,in To preset the bending radius, The bending empirical coefficient is a pre-calibrated constant for the silicone / polyester material system of the outer braided structure of the charging cable; The bending guide device is based on calculations. Adjust the bending radius to maintain the preset bending radius of the wire during the curing process, while performing segmented gradient curing treatment.

7. The optimized method for UV adhesive penetration and curing of high-current silicone braided charging cables as described in claim 1, characterized in that, In step S6, the wire is briefly heated using an infrared heat treatment device to eliminate internal stress generated during the curing process, including: The heating temperature and heating time of the infrared heat treatment device are adjusted according to the pitch density of the outer layer of the wire braided structure, wherein the pitch density is the average spacing parameter between adjacent fibers in the braided structure. The pitch density is inversely proportional to the heating temperature, and the pitch density is directly proportional to the heating time. The adjustment mechanism is implemented through a pre-built heat treatment parameter library, which is calibrated based on the typical physical characteristics of the outer layer of the charging cable's braided structure, and the heat treatment parameters are matched with the inherent characteristics of the braided structure.

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