High-strength high-wear-resistance cable and preparation method thereof

Abstract

The application relates to the technical field of cables, and discloses a high-strength and high-wear-resistance cable and a preparation method thereof. The high-strength and high-wear-resistance cable comprises, from inside to outside, a conductor, a conductor shielding layer, an insulation layer, a braided shielding layer and a sheath layer. The conductor is composed of multiple tin-plated copper wires. The raw materials of the sheath layer comprise the following components in parts by weight: butadiene styrene rubber 60-80 parts, butyronitrile rubber 20-30 parts, fillers 30-40 parts, molybdenum disulfide 5-8 parts, an activator 4-6 parts, aromatic oil 2-4 parts, an anti-aging agent 3-5 parts, a vulcanizing agent 2-4 parts and a promoter 3-5 parts. The above technical scheme solves the problems of insufficient strength and wear resistance of the cable sheath layer in the related art.

Description

Technical Field

[0001] This invention relates to the field of cable technology, specifically to a high-strength, high-wear-resistant cable and its preparation method. Background Technology

[0002] Cables, as the core carriers of power transmission and signal conduction, are widely used in various fields such as industrial manufacturing, mining, construction engineering, and transportation. However, with the rapid development of industry, the operating environment of cables is becoming increasingly complex and demanding, which places higher requirements on cable performance.

[0003] Currently, the strength and abrasion resistance of cable sheaths are limited. In scenarios such as underground mines, metallurgical workshops, and ports, cables must withstand long-term mechanical actions such as dragging, friction, and compression. This not only continuously wears down the cable sheath, leading to sheath damage and reduced cable protection performance, but may also cause internal conductor deformation, structural loosening, or even breakage. Therefore, developing a cable that combines high strength and high abrasion resistance is of great significance. Summary of the Invention

[0004] This invention proposes a high-strength, high-wear-resistant cable and its preparation method, which solves the problem of insufficient strength and wear resistance of the cable sheath layer in related technologies.

[0005] The technical solution of the present invention is as follows: This invention proposes a high-strength, high-wear-resistant cable, comprising, from the inside out, a conductor, a conductor shielding layer, an insulation layer, a braided shielding layer, and a sheath layer. The conductor is made of multiple strands of tin-plated copper wire. The raw materials of the sheath layer include the following components by weight: 60-80 parts of styrene-butadiene rubber, 20-30 parts of nitrile rubber, 30-40 parts of filler, 5-8 parts of molybdenum disulfide, 4-6 parts of activator, 2-4 parts of aromatic oil, 3-5 parts of antioxidant, 2-4 parts of vulcanizing agent, and 3-5 parts of accelerator.

[0006] As a further technical solution, the material of the conductor shielding layer is semiconductor polypropylene.

[0007] As a further technical solution, the insulation layer is a cross-linked polyethylene insulation layer.

[0008] As a further technical solution, the braided shielding layer is a tin-plated copper wire braided shielding layer.

[0009] As a further technical solution, the filler comprises the following components in parts by weight: 100 parts of silica, 6-7 parts of hydroxyl acrylic acid dispersion, and 2-4 parts of silane coupling agent.

[0010] This invention improves the strength and abrasion resistance of cable sheathing by adding silica modified with hydroxyl acrylic acid dispersion and silane coupling agent as a filler. While silica, as a reinforcing agent, effectively enhances the strength and abrasion resistance of the sheathing, its tendency to agglomerate hinders its full effect. The hydroxyl acrylic acid dispersion, containing hydroxyl and carboxyl groups, forms hydrogen bonds with the hydroxyl groups on the silica surface. Simultaneously, its long-chain polymer molecules further improve the dispersibility of silica through steric hindrance, thereby enhancing the tensile strength and abrasion resistance of the cable sheathing. Furthermore, the alkoxy groups of the silane coupling agent form covalent bonds with the hydroxyl groups on the silica surface, further improving the dispersibility of silica and thus further enhancing the tensile strength and abrasion resistance of the cable sheathing.

[0011] As a further technical solution, the mass ratio of the silica, hydroxyacrylic acid dispersion and silane coupling agent is 100:6:2~4, preferably 100:6:3.

[0012] As a further technical solution, the preparation method of the filler includes the following steps: after the hydroxy acrylic acid dispersion and silane coupling agent are evenly dispersed in a solvent, fumed silica is added and mixed, and then filtered and dried to obtain the filler.

[0013] As a further technical solution, the solvent is water.

[0014] As a further technical solution, the mixing temperature is 30~40℃ and the mixing time is 1~2h.

[0015] As a further technical solution, the styrene-butadiene rubber is composed of a first styrene-butadiene rubber and a second styrene-butadiene rubber, wherein the weight ratio of styrene structural units to butadiene structural units in the first styrene-butadiene rubber and the second styrene-butadiene rubber is different.

[0016] As a further technical solution, the weight ratio of styrene structural units to butadiene structural units in the first styrene-butadiene rubber is 28 / 72, and the weight ratio of styrene structural units to butadiene structural units in the second styrene-butadiene rubber is 40 / 60.

[0017] This invention improves the abrasion resistance of cable sheathing layers by compounding a first styrene-butadiene rubber with a styrene / butadiene structural unit weight ratio of 28 / 72 and a second styrene-butadiene rubber with a styrene / butadiene structural unit weight ratio of 40 / 60. The first styrene-butadiene rubber with a styrene / butadiene structural unit weight ratio of 28 / 72 has a lower styrene content, resulting in higher molecular chain flexibility and giving the sheathing layer better elasticity and toughness. Under friction, it can effectively buffer and disperse stress through deformation, reducing surface damage. Meanwhile, the styrene... The second styrene-butadiene rubber, with a weight ratio of 40 / 60 for ethylene structural units and butadiene structural units, has a high styrene content, which can improve the hardness and modulus of the sheath layer and enhance its resistance to scratches and cuts. After compounding, the second styrene-butadiene rubber can effectively avoid the problem of insufficient scratch and cut resistance of the sheath layer due to the excessive flexibility of the first styrene-butadiene rubber. The first styrene-butadiene rubber can avoid the problem of reduced wear resistance caused by the excessive hardness and brittleness of the second styrene-butadiene rubber. Therefore, the compounding of the first and second styrene-butadiene rubbers in this invention improves the wear resistance of the cable sheath layer.

[0018] As a further technical solution, the mass ratio of the first styrene-butadiene rubber and the second styrene-butadiene rubber is 40:20~25, preferably 40:23.

[0019] As a further technical solution, the activator includes one or more of zinc oxide, stearic acid, and zinc stearate.

[0020] As a further technical solution, the antioxidant includes one or more of antioxidant RD, antioxidant 2246, and antioxidant 4010NA.

[0021] As a further technical solution, the vulcanizing agent is sulfur.

[0022] As a further technical solution, the accelerator includes accelerator DM, accelerator CZ, and accelerator DBU. One or more of B.

[0023] This invention also proposes a method for preparing a high-strength, high-abrasion-resistant cable, comprising the following steps: S1. Extruding the conductor shielding material onto the outside of the conductor to form a conductor shielding layer; S2. Extruding the insulating layer material onto the outside of the conductor shielding layer to form an insulating layer; S3. Weave the braided shielding material onto the outside of the insulation layer to form a braided shielding layer; S4. After the raw materials of the sheath layer are mixed evenly, they are melt-extruded and wrapped around the outside of the braided shielding layer, vulcanized, to form the sheath layer and obtain a high-strength and high-wear-resistant cable.

[0024] The working principle and beneficial effects of this invention are as follows: This invention provides a high-strength, high-wear-resistant cable. From the inside out, the cable comprises a conductor, a conductor shielding layer, an insulation layer, a braided shielding layer, and a sheath layer, forming a multi-layered, synergistic protection system. The conductor is composed of multiple strands of tin-plated copper wire, enhancing the cable's flexibility and current-carrying capacity, ensuring stable transmission. The conductor shielding layer effectively eliminates electric field concentration, while the insulation layer prevents leakage. The braided shielding layer resists electromagnetic interference and further strengthens the overall structure of the cable. The sheath layer uses a composite base of styrene-butadiene rubber and nitrile rubber, improving its strength and wear resistance. The various layers work together to achieve the cable's high strength, high wear resistance, and stable transmission performance. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0026] In the following examples and comparative examples: The first styrene-butadiene rubber has a styrene structural unit to butadiene structural unit content weight ratio of 28 / 72, model: YH-793, manufacturer: Shenzhen Yoshida Chemical Co., Ltd. The styrene structural unit to butadiene structural unit content of the second styrene-butadiene rubber is 40 / 60 by weight. Model: YH-792. Manufacturer: Shenzhen Yoshida Chemical Co., Ltd. Nitrile rubber, model: N41E, manufacturer: Lanzhou Petrochemical Branch of China National Petroleum Corporation; Sulfur, type: S60; Hydroxyacrylic acid dispersion, model: PT-2001K, solid content: 40wt%, manufacturer: Guangzhou Lvbao New Materials Co., Ltd.; The silica is precipitated silica with an average particle size of 30 nm. Aromatic oil, type: D60.

[0027] Example 1 A high-strength, high-wear-resistant cable comprises, from the inside out, a conductor, a conductor shielding layer, an insulation layer, a braided shielding layer, and a sheath layer; wherein the raw materials of the sheath layer include the following components by weight: 60 parts styrene-butadiene rubber, 20 parts nitrile rubber, 30 parts filler, 5 parts molybdenum disulfide, 3 parts zinc oxide, 1 part stearic acid, 2 parts aromatic oil, 3 parts antioxidant RD, 2 parts sulfur, and 3 parts accelerator DM, wherein the styrene-butadiene rubber is the first type of styrene-butadiene rubber; The preparation method of the filler includes the following steps: After the hydroxy acrylic acid dispersion and silane coupling agent KH-550 are evenly dispersed in water, silica is added and mixed at 30°C for 2 hours. After filtration and drying, the filler is obtained. The mass-volume ratio of silica to water is 1g:15mL, and the mass ratio of silica, hydroxy acrylic acid dispersion and silane coupling agent KH-550 is 50:3:1. A method for preparing a high-strength, high-abrasion-resistant cable includes the following steps: S1. Extruding semiconductor polypropylene material onto the outside of a conductor made of 19 strands of tin-plated copper wire to form a conductor shielding layer; S2. Extruding cross-linked polyethylene material onto the outside of the conductor shielding layer to form an insulating layer; S3. Braid tin-plated copper wires onto the outside of the insulation layer to form a braided shielding layer; S4. After the raw materials of the sheath layer are mixed evenly, they are melt-extruded and wrapped on the outside of the braided shield layer, vulcanized, to form the sheath layer and obtain a high-strength and high-wear-resistant cable.

[0028] Example 2 A high-strength, high-wear-resistant cable comprises, from the inside out, a conductor, a conductor shielding layer, an insulation layer, a braided shielding layer, and a sheath layer; wherein the raw materials of the sheath layer include the following components by weight: 70 parts styrene-butadiene rubber, 25 parts nitrile rubber, 35 parts filler, 7 parts molybdenum disulfide, 3 parts zinc oxide, 2 parts stearic acid, 3 parts aromatic oil, 4 parts antioxidant RD, 3 parts sulfur, and 4 parts accelerator DM, wherein the styrene-butadiene rubber is the first type of styrene-butadiene rubber; The preparation method of the filler includes the following steps: After the hydroxy acrylic acid dispersion and silane coupling agent KH-550 are evenly dispersed in water, silica is added and mixed at 35°C for 1.5 h. After filtration and drying, the filler is obtained. The mass-volume ratio of silica to water is 1 g: 15 mL, and the mass ratio of silica, hydroxy acrylic acid dispersion and silane coupling agent KH-550 is 50:3:1. A method for preparing a high-strength, high-abrasion-resistant cable includes the following steps: S1. Extruding semiconductor polypropylene material onto the outside of a conductor made of 19 strands of tin-plated copper wire to form a conductor shielding layer; S2. Extruding cross-linked polyethylene material onto the outside of the conductor shielding layer to form an insulating layer; S3. Braid tin-plated copper wires onto the outside of the insulation layer to form a braided shielding layer; S4. After the raw materials of the sheath layer are mixed evenly, they are melt-extruded and wrapped on the outside of the braided shield layer, vulcanized, to form the sheath layer and obtain a high-strength and high-wear-resistant cable.

[0029] Example 3 A high-strength, high-wear-resistant cable comprises, from the inside out, a conductor, a conductor shielding layer, an insulation layer, a braided shielding layer, and a sheath layer; wherein the raw materials of the sheath layer include the following components by weight: 80 parts styrene-butadiene rubber, 30 parts nitrile rubber, 40 parts filler, 8 parts molybdenum disulfide, 4 parts zinc oxide, 2 parts stearic acid, 4 parts aromatic oil, 5 parts antioxidant RD, 4 parts sulfur, and 5 parts accelerator DM, wherein the styrene-butadiene rubber is the first type of styrene-butadiene rubber; The preparation method of the filler includes the following steps: After the hydroxy acrylic acid dispersion is evenly dispersed in water, silica and silane coupling agent KH-550 are added and mixed at 40°C for 1 hour. After filtration and drying, the filler is obtained. The mass-volume ratio of silica to water is 1g:15mL, and the mass ratio of silica, hydroxy acrylic acid dispersion and silane coupling agent KH-550 is 50:3:1. A method for preparing a high-strength, high-abrasion-resistant cable includes the following steps: S1. Extruding semiconductor polypropylene material onto the outside of a conductor made of 19 strands of tin-plated copper wire to form a conductor shielding layer; S2. Extruding cross-linked polyethylene material onto the outside of the conductor shielding layer to form an insulating layer; S3. Braid tin-plated copper wires onto the outside of the insulation layer to form a braided shielding layer; S4. After the raw materials of the sheath layer are mixed evenly, they are melt-extruded and wrapped on the outside of the braided shield layer, vulcanized, to form the sheath layer and obtain a high-strength and high-wear-resistant cable.

[0030] Example 4 The only difference between this embodiment and Example 2 is that the mass ratio of silica, hydroxyacrylic acid dispersion and silane coupling agent KH-550 in this embodiment is 100:6:3.

[0031] Example 5 The only difference between this embodiment and Example 2 is that the mass ratio of silica, hydroxyacrylic acid dispersion and silane coupling agent KH-550 in this embodiment is 50:3:2.

[0032] Example 6 The only difference between this embodiment and Embodiment 2 is that the styrene-butadiene rubber in this embodiment is a second type of styrene-butadiene rubber.

[0033] Example 7 The only difference between this embodiment and Embodiment 2 is that in this embodiment, the styrene-butadiene rubber is composed of a first styrene-butadiene rubber and a second styrene-butadiene rubber with a mass ratio of 2:1.

[0034] Example 8 The only difference between this embodiment and Embodiment 2 is that in this embodiment, the styrene-butadiene rubber is composed of a first styrene-butadiene rubber and a second styrene-butadiene rubber with a mass ratio of 40:23.

[0035] Example 9 The only difference between this embodiment and Embodiment 2 is that in this embodiment, the styrene-butadiene rubber is composed of a first styrene-butadiene rubber and a second styrene-butadiene rubber with a mass ratio of 8:5.

[0036] Comparative Example 1 The only difference between this comparative example and Example 1 is that the filler in this comparative example is silica.

[0037] Comparative Example 2 The only difference between this comparative example and Example 1 is that the hydroxy acrylic acid dispersion is replaced with an equal amount of silane coupling agent KH-550 in this comparative example.

[0038] Comparative Example 3 The only difference between this comparative example and Example 1 is that the silane coupling agent KH-550 is replaced with an equal amount of hydroxyacrylic acid dispersion in this comparative example.

[0039] Experimental Example 1 The sheath layers of the cables prepared in Examples 1-9 and Comparative Examples 1-3 were tested according to the following method: 1. Tensile strength: The tensile strength was tested according to GB / T 528-2009 "Determination of tensile stress-strain properties of vulcanized rubber or thermoplastic rubber". The sheath layer specimen was a type 1 dumbbell-shaped specimen, and the test speed was 500 mm / min. The test results are shown in Table 1 below.

[0040] 2. Abrasion resistance: The relative volume abrasion was tested according to GB / T 9867-2008 "Determination of abrasion resistance of vulcanized rubber or thermoplastic rubber (rotary roller abrasion tester method)". The abrasive cloth was calibrated using method A and standard reference rubber No. 1. The results are the average values ​​of three samples. The test results are shown in Table 1 and Table 2 below.

[0041] Table 1 Performance test results of Examples 1-5 and Comparative Examples 1-3

[0042] The tensile strength of Examples 1-5 is higher than that of Comparative Examples 1-3, and the relative volumetric wear of Examples 1-5 is lower than that of Comparative Examples 1-3. This indicates that the present invention improves the tensile strength and wear resistance of the cable sheath by adding silica modified with hydroxyl acrylic dispersion and silane coupling agent KH-550 as filler to the cable sheath layer.

[0043] Table 2 Performance test results of Examples 2 and 6-9

[0044] The relative volumetric wear of Examples 7-9 is lower than that of Examples 2 and 6, indicating that the present invention improves the wear resistance of the sheath layer by compounding a first styrene-butadiene rubber with a styrene structural unit to butadiene structural unit content weight ratio of 28 / 72 and a second styrene-butadiene rubber with a styrene structural unit to butadiene structural unit content weight ratio of 40 / 60.

[0045] The above are merely preferred embodiments of the present invention and are 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. A high-strength, high-wear-resistant cable, characterized in that, From the inside out, the structure consists of a conductor, a conductor shielding layer, an insulation layer, a braided shielding layer, and a sheath layer. The conductor is made of multiple strands of tin-plated copper wire. The raw materials of the sheath layer include the following components by weight: 60-80 parts of styrene-butadiene rubber, 20-30 parts of nitrile rubber, 30-40 parts of filler, 5-8 parts of molybdenum disulfide, 4-6 parts of activator, 2-4 parts of aromatic oil, 3-5 parts of antioxidant, 2-4 parts of vulcanizing agent, and 3-5 parts of accelerator.

2. The high-strength, high-wear-resistant cable according to claim 1, characterized in that, The material of the conductor shielding layer is semiconductor polypropylene.

3. The high-strength, high-wear-resistant cable according to claim 1, characterized in that, The insulation layer is a cross-linked polyethylene insulation layer.

4. The high-strength, high-wear-resistant cable according to claim 1, characterized in that, The braided shielding layer is a tin-plated copper wire braided shielding layer.

5. A high-strength, high-wear-resistant cable according to claim 1, characterized in that, The filler comprises the following components in parts by weight: 100 parts of silica, 6-7 parts of hydroxyl acrylic acid dispersion, and 2-4 parts of silane coupling agent.

6. A high-strength, high-wear-resistant cable according to claim 5, characterized in that, The mass ratio of the silica, hydroxyacrylic acid dispersion and silane coupling agent is 100:6:2~4.

7. A high-strength, high-wear-resistant cable according to claim 5, characterized in that, The preparation method of the filler includes the following steps: after the hydroxy acrylic acid dispersion and silane coupling agent are evenly dispersed in a solvent, silica is added and mixed, and the filler is obtained by filtration and drying.

8. A high-strength, high-wear-resistant cable according to claim 1, characterized in that, The styrene-butadiene rubber is composed of a first styrene-butadiene rubber and a second styrene-butadiene rubber, wherein the weight ratio of styrene structural units to butadiene structural units in the first styrene-butadiene rubber and the second styrene-butadiene rubber is different.

9. A high-strength, high-wear-resistant cable according to claim 8, characterized in that, The weight ratio of styrene structural units to butadiene structural units in the first styrene-butadiene rubber is 28:72, and the weight ratio of styrene structural units to butadiene structural units in the second styrene-butadiene rubber is 40:

60.

10. A method for preparing a high-strength, high-abrasion-resistant cable, used to prepare the high-strength, high-abrasion-resistant cable according to any one of claims 1 to 9, characterized in that, Includes the following steps: S1. Extruding the conductor shielding material onto the outside of the conductor to form a conductor shielding layer; S2. Extruding the insulating layer material onto the outside of the conductor shielding layer to form an insulating layer; S3. Weave the braided shielding material onto the outside of the insulation layer to form a braided shielding layer; S4. After the raw materials of the sheath layer are mixed evenly, they are melt-extruded and wrapped around the outside of the braided shielding layer, vulcanized, to form the sheath layer and obtain a high-strength and high-wear-resistant cable.

Images