A mixing process of high-speed data line shielding material

Abstract

This disclosure presents a mixing process for a high-speed data cable shielding material. The specific implementation of this process includes: controlling the forward rotation of a mixing spindle for coarse mixing and collecting real-time torque values ​​to calculate the torque transient fluctuation coefficient; when the coefficient meets a first condition, reducing the rotation speed and controlling the spindle to superimpose axial reciprocating pulsations, while simultaneously controlling the spindle rotation to follow an intermittent temporal cycle and maintaining the axial reciprocating pulsations during the resting period; when the coefficient decays to a second condition, terminating the axial reciprocating pulsations and increasing the rotation speed for distributed mixing; and at the end of the process, controlling the spindle to alternately operate in both forward and reverse directions. This implementation utilizes the spatial displacement field and the intermittent relaxation of the time axis to collaboratively and layer-by-layer fractally peel away filler agglomerates, using shear energy spatial retreat to suppress local melt viscosity dissipation and heat dissipation, preserving the long-chain resin skeleton, synergistically improving the elongation at break of the finished shielding material, and eliminating flow dead zones.

Description

Technical Field

[0001] The embodiments disclosed herein relate to the field of multiphase material blending manufacturing technology, specifically to a blending process for a high-speed data line shielding material. Background Technology

[0002] Current conventional methods rely on a fixed geometric structure within the mixing chamber to continuously input spatially symmetrical mechanical shear kinetic energy into the multiphase system via an axial stirring axis. This overcomes interparticle attraction and drives the shielding powder to disperse within the resin matrix. However, in the initial stage of blending, the high-density functional conductive powder, upon entering the mixing chamber, spontaneously agglomerates due to surface strain energy. This causes a sharp increase in the transient viscosity of the multiphase fluid and the spontaneous formation of a dense network of large, unmelted agglomerates. When the stirring shaft maintains a constant high-speed rotation to output a shear field, the shear kinetic energy is concentrated and dissipated as heat around the large agglomerate network, transforming into viscous growth. Heat causes excessive thermomechanical chain scission damage to the long-chain molecular structure of the resin matrix and breaks down the high aspect ratio conductive powder. In order to suppress the damage caused by local temperature overload due to viscous dissipation, the conventional path of linearly reducing the rotation speed of the stirring shaft will cause the multiphase fluid to be locked inside the fixed closed laminar streamline trajectory, so that the rotational power cannot effectively penetrate the stress core of the large-size agglomerate network. This will generate a large-scale flow stagnation dead zone in the zero velocity region of the mixing chamber wall, which will worsen the dispersion and dissociation rate of conductive powder particles and cause the internal conductive topology network of the finished product to exhibit an uneven anisotropic spatial distribution.

[0003] Optimizing the physical geometry of the mixing components can alleviate material accumulation to some extent, but the control method still adopts a fixed rigid adjustment strategy, which is still difficult to cope with the transient changes in the rheological state of materials in complex multiphase systems. For example, Chinese invention patent application CN113665022A discloses a high-filling dual-rotor mixing screw, which expands the mixing area and assists in heat dissipation by axially staggering the intersection points of the screw edges. However, this scheme relies on the underlying assumption that multiphase materials have stable rheological characteristics in the mixing chamber. When faced with the actual blending conditions of functional fillers with extremely high filling density and high surface energy, the viscosity of the multiphase melt will suddenly and monotonically increase due to the spontaneous construction of the agglomeration network. At this time, the static physical structure cannot dynamically reconstruct the shear energy configuration on the spatiotemporal axis. Under constant unidirectional rotation control, the mechanical shear kinetic energy is still excessively dissipated in the high-viscosity local area and converted into high viscous heat generation, destroying the long-chain resin skeleton and the length-to-diameter ratio of the filler. Establishing a dynamic reconstruction mechanism based on real-time feedback of the flow field rheological characteristics at the control level has become the key to breaking through the bottleneck of high-filling mixing.

[0004] Therefore, when proposing a mixing process for a high-speed data line shielding material, the technical problem to be solved by this invention is how to implement the nonlinear reconstruction of shear energy configuration on the spacetime axis based on the transient torque fluctuation characteristics of the multiphase fluid in the mixing chamber, and eliminate the inherent flow hindrance blind zone on the chamber wall through multi-degree-of-freedom linkage of the stirring spindle, thereby constructing a globally uniformly distributed isotropic conductive topology network while maintaining the complete long-chain matrix of resin molecules and the aspect ratio of functional particles. Summary of the Invention

[0005] The summary portion of this disclosure is intended to provide a brief overview of the concepts, which will be described in detail in the detailed description portion. This summary portion is not intended to identify key or essential features of the claimed technical solutions, nor is it intended to limit the scope of the claimed technical solutions.

[0006] Some embodiments of this disclosure propose a mixing process for high-speed data line shielding materials to address the technical problems mentioned in the background section above.

[0007] In a first aspect, some embodiments of this disclosure provide a mixing process for a high-speed data cable shielding material, the process comprising:

[0008] Step S1: The polymer resin matrix and conductive filler are put into the mixing chamber;

[0009] Step S2: Drive the mixing spindle to rotate the components in the mixing chamber in the forward direction, perform convective coarse mixing at an initial speed of 450 rpm, and collect the real-time torque value of the mixing spindle.

[0010] Step S3: Calculate the torque transient fluctuation coefficient based on the comparison result between the real-time torque value and the preset rated torque reference value; when the torque transient fluctuation coefficient is greater than or equal to 0.40 and lasts for 3.0s, reduce the rotational speed of the mixing spindle to 200rpm, and control the mixing spindle to perform axial reciprocating motion with a frequency of 3.5Hz and a reciprocating displacement of 15mm; simultaneously control the rotational operation of the mixing spindle to follow an alternating time cycle of 4.0s working and 1.5s resting, and maintain the axial reciprocating motion during the resting period;

[0011] Step S4: Continuously update the torque transient fluctuation rate coefficient. When the torque transient fluctuation rate coefficient is less than or equal to 0.15 and lasts for 2.5s, terminate the axial reciprocating motion and increase the rotational speed of the mixing spindle to 830rpm for distributed mixing. The duration of the distributed mixing is 300s.

[0012] Step S5: When the distribution mixing has been performed for 290 seconds, the rotation direction of the mixing spindle is changed, and the mixing spindle is controlled to perform 4 alternating forward and reverse cycles at a speed of 250 rpm.

[0013] Preferably, in step S2, the axial reciprocating motion and the rotational motion of the mixing spindle together induce a complex flow in the mixing chamber, generating a gradient flow field shear velocity in the axial space of the mixing chamber, causing the locally agglomerated particles of the conductive filler to disperse into loose particles under the action of the alternating stress.

[0014] Preferably, in step S3, the alternating timing cycle is repeated 10 to 15 times; during the stationary period of the rotating operation of the mixing spindle, the axial reciprocating pulsation frequency of the mixing spindle is controlled by the axial pulsation drive mechanism to be 2 Hz to 5 Hz, and the axial reciprocating displacement is 8 mm to 15 mm. The axial shear laminar flow caused by the axial reciprocating motion reduces the accumulation of internal heat energy in the mixing chamber and controls the temperature rise rate in the mixing chamber to be less than 0.3 ℃ / min.

[0015] Preferably, in step S3, the calculation procedure for the torque transient fluctuation coefficient is as follows: the process parameter controller collects the real-time torque data of the mixing spindle at a sampling period of 10ms, and calculates the ratio of the standard deviation to the mean of the torque within 250 consecutive sampling points, and determines the ratio as the torque transient fluctuation coefficient.

[0016] Preferably, step S4 includes the following sub-steps: step S41, controlling the mixing spindle to maintain a speed of 830 rpm for 200 s to break the residual network of the conductive filler; step S42, controlling the mixing spindle to maintain this speed for the next 100 s to drive the dispersed conductive filler to flow and convect in the polymer resin matrix, thereby completing the homogenization distribution of the mixed material.

[0017] Preferably, the material fed into the mixing chamber comprises 100% of the total mass of the high-speed data line shielding material, with carbon nanotubes accounting for 15% to 25% of the mass and conductive carbon black accounting for 30% to 40% of the mass, and the remainder being polyethylene resin as the polymer resin matrix.

[0018] Preferably, in step S5, the process parameter controller switches the rotation direction of the mixing spindle, controls the mixing spindle to operate at a reverse speed of 250 rpm, the duration of a single reverse rotation is 1.5s to 3s, and the forward and reverse rotation cycles are repeated 4 times.

[0019] Preferably, the polymer resin matrix is ​​linear low-density polyethylene, which has a melt index of 0.8 g / 10 min to 1.2 g / 10 min and a density of 0.918 g / cm³ to 0.922 g / cm³ at 190°C and a load of 2.16 kg.

[0020] Preferably, after step S5 is completed, the elongation at break of the finished high-speed data line shielding material is not less than 150%, and the volume resistivity is not higher than 10 Ω·cm.

[0021] The above-described embodiments of this disclosure have the following beneficial effects:

[0022] 1. In the mixing process of high-speed data cable shielding material, the torque transient fluctuation rate coefficient, which characterizes the strain energy of the packing agglomeration network, is obtained by solving the differential quotient between the real-time torque of the main shaft and the system parameters. When the first switching boundary condition is reached, the rotation speed is reduced, and a spatially asymmetric reciprocating pulsating displacement field is injected into the fluid. The lower rotation speed and the high-frequency axial reciprocating pulsation work together to induce alternating mechanical stress waves propagating along the axis of the stirring main shaft in the mixing flow field. These waves act perpendicularly on the stress defects at the contact phase interface between the packing particles, peeling off large-sized packing agglomerates layer by layer from the outside to the inside. From the perspective of fluid dynamics shear network reconstruction, the spatial retreat of rotational shear energy is used to suppress the viscous heat dissipation of local high-viscosity fluids. While optimizing the macroscopic and microscopic mixing uniformity of multiphase fluids, the thermomechanical chain degradation of long polymer matrix chains is blocked.

[0023] 2. During the axial pulsating stress penetration stage, a stepped intermittent shearing sequence is forcibly applied to control the rotation of the stirring shaft and follow a periodic alternation of fixed working time and resting time. Meanwhile, the hydraulic axial movement continues to operate during the rotation and resting period. Utilizing the inherent shear thinning hysteresis effect of multiphase material fluids, the polymer chain segments achieve in-situ stress relaxation and self-heating conduction within the resting window where external rotational flow resistance is lost. This achieves precise in-situ temperature control without the introduction of external cooling medium, inhibits the rate of temperature rise, and avoids secondary mechanical cutting of the length-to-diameter ratio of the stripped powder filler caused by continuous shearing, thus maintaining the stability of the isotropy of the functional particle spatial network.

[0024] 3. Under the action of spatial asymmetric alternating stress waves, the agglomerated network of the filler to be filled disintegrates into independent loose particles. When the multiphase fluid tends to a stable rheological state and the transient fluctuation coefficient of the torque of the stirring shaft decays to the second switching boundary condition, the hydraulic axial pulsation is stopped and the mechanical speed is increased sharply to the third shear rate. The dissociated fine conductive particles exhibit global Brownian diffusion in the low-viscosity pseudoplastic melt, which is a high-viscosity mixing medium. The high shear force of the flow field efficiently overcomes the van der Waals force resistance between fine filler particles without destroying the molecular chain, and completes the hydrodynamic homogenization, dispersion and mixing of multiphase fluid components. Combined with the long-chain preservation skeleton without overheating loss in the front section, it synergistically improves the elongation at break and physical and mechanical toughness of the finished shielding material. Attached Figure Description

[0025] The above and other features, advantages, and aspects of the embodiments of this disclosure will become more apparent from the accompanying drawings and the following detailed description. Throughout the drawings, the same or similar reference numerals denote the same or similar elements. It should be understood that the drawings are schematic, and elements are not necessarily drawn to scale.

[0026] Figure 1 This is a flow chart of the high-speed data cable shielding material mixing process of the present invention;

[0027] Figure 2 This is a diagram illustrating the components of the high-speed data cable shielding material mixing process of the present invention.

[0028] Figure 3 This is a diagram of the control system architecture for the high-speed data cable shielding material mixing process of the present invention. Detailed Implementation

[0029] Embodiments of this disclosure will now be described in more detail with reference to the accompanying drawings. While some embodiments of this disclosure are shown in the drawings, it should be understood that this disclosure can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of this disclosure. It should be understood that the accompanying drawings and embodiments of this disclosure are for illustrative purposes only and are not intended to limit the scope of protection of this disclosure.

[0030] It should also be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings. Unless otherwise specified, the embodiments and features described in this disclosure can be combined with each other.

[0031] It should be noted that the concepts of "first" and "second" mentioned in this disclosure are used only to distinguish different devices, modules or units, and are not used to limit the order of functions performed by these devices, modules or units or their interdependencies.

[0032] It should be noted that the terms "a" and "a plurality of" used in this disclosure are illustrative rather than restrictive, and those skilled in the art should understand that, unless otherwise expressly indicated in the context, they should be understood as "one or more".

[0033] The names of messages or information exchanged between multiple devices in the embodiments of this disclosure are for illustrative purposes only and are not intended to limit the scope of such messages or information.

[0034] Before performing any of the operations involving the collection, storage, processing, or use of the target images disclosed herein, the relevant organizations or individuals shall fulfill their obligations, including conducting information security impact assessments, informing the information subjects, and obtaining prior authorization and consent from the information subjects.

[0035] This disclosure will now be described in detail with reference to the accompanying drawings and embodiments.

[0036] refer to Figure 1 The diagram illustrates a flow chart of some embodiments of a mixing process for a high-speed data cable shielding material according to the present disclosure. The mixing process for this high-speed data cable shielding material includes the following steps:

[0037] Step S1: The polymer resin matrix and conductive filler are put into the mixing chamber;

[0038] Step S2: Drive the mixing spindle to rotate the components in the mixing chamber in the forward direction, perform convective coarse mixing at an initial speed of 450 rpm, and collect the real-time torque value of the mixing spindle.

[0039] Step S3: Calculate the torque transient fluctuation coefficient based on the comparison result between the real-time torque value and the preset rated torque reference value; when the torque transient fluctuation coefficient is greater than or equal to 0.40 and lasts for 3.0s, reduce the rotational speed of the mixing spindle to 200rpm, and control the mixing spindle to perform axial reciprocating motion with a frequency of 3.5Hz and a reciprocating displacement of 15mm; simultaneously control the rotational operation of the mixing spindle to follow an alternating time cycle of 4.0s working and 1.5s resting, and maintain the axial reciprocating motion during the resting period;

[0040] Step S4: Continuously update the torque transient fluctuation rate coefficient. When the torque transient fluctuation rate coefficient is less than or equal to 0.15 and lasts for 2.5s, terminate the axial reciprocating motion and increase the rotational speed of the mixing spindle to 830rpm for distributed mixing. The duration of the distributed mixing is 300s.

[0041] Step S5: When the distribution mixing has been performed for 290 seconds, the rotation direction of the mixing spindle is changed, and the mixing spindle is controlled to perform 4 alternating forward and reverse cycles at a speed of 250 rpm.

[0042] Preferably, in step S2, the axial reciprocating motion and the rotational motion of the mixing spindle together induce a complex flow in the mixing chamber, generating a gradient flow field shear velocity in the axial space of the mixing chamber, causing the locally agglomerated particles of the conductive filler to disperse into loose particles under the action of the alternating stress.

[0043] Preferably, in step S3, the alternating timing cycle is repeated 10 to 15 times; during the stationary period of the rotating operation of the mixing spindle, the axial reciprocating pulsation frequency of the mixing spindle is controlled by the axial pulsation drive mechanism to be 2 Hz to 5 Hz, and the axial reciprocating displacement is 8 mm to 15 mm. The axial shear laminar flow caused by the axial reciprocating motion reduces the accumulation of internal heat energy in the mixing chamber and controls the temperature rise rate in the mixing chamber to be less than 0.3 ℃ / min.

[0044] Preferably, in step S3, the calculation procedure for the torque transient fluctuation coefficient is as follows: the process parameter controller collects the real-time torque data of the mixing spindle at a sampling period of 10ms, and calculates the ratio of the standard deviation to the mean of the torque within 250 consecutive sampling points, and determines the ratio as the torque transient fluctuation coefficient.

[0045] Preferably, step S4 includes the following sub-steps: step S41, controlling the mixing spindle to maintain a speed of 830 rpm for 200 s to break the residual network of the conductive filler; step S42, controlling the mixing spindle to maintain this speed for the next 100 s to drive the dispersed conductive filler to flow and convect in the polymer resin matrix, thereby completing the homogenization distribution of the mixed material.

[0046] Preferably, the material fed into the mixing chamber comprises 100% of the total mass of the high-speed data line shielding material, with carbon nanotubes accounting for 15% to 25% of the mass and conductive carbon black accounting for 30% to 40% of the mass, and the remainder being polyethylene resin as the polymer resin matrix.

[0047] Preferably, in step S5, the process parameter controller switches the rotation direction of the mixing spindle, controls the mixing spindle to operate at a reverse speed of 250 rpm, the duration of a single reverse rotation is 1.5s to 3s, and the forward and reverse rotation cycles are repeated 4 times.

[0048] Preferably, the polymer resin matrix is ​​linear low-density polyethylene, which has a melt index of 0.8 g / 10 min to 1.2 g / 10 min and a density of 0.918 g / cm³ to 0.922 g / cm³ at 190°C and a load of 2.16 kg.

[0049] Preferably, after step S5 is completed, the elongation at break of the finished high-speed data line shielding material is not less than 150%, and the volume resistivity is not higher than 10 Ω·cm.

[0050] Example 1: When the equipment is in industrial operation for blending high-performance, high-speed data cable shielding materials, linear low-density polyethylene and 35% by mass of modified multilayer graphene conductive powder are introduced into the mixing chamber. The high-density modified multilayer graphene conductive powder rapidly aggregates and forms a large-size agglomerate network due to surface energy upon entering the mixing chamber. This causes a nonlinear monotonic abrupt change in the local dynamic viscosity of the multiphase plastic melt. The traditional continuous constant high-shear flow field cannot penetrate the internal stress core of the large-size agglomerate network. Intense mechanical collisions lead to physical damage to the high aspect ratio filler structure, and the localized energy concentration and dissipation induce... Thermomechanical degradation and long-chain breakage of the matrix polymer chains, if low-shear control is implemented to protect the matrix long chains, results in insufficient convective exchange force in the melt and the creation of a global laminar flow dead zone within the mixing chamber. This leads to a deterioration in the mass transfer efficiency of the multiphase material and causes heterogeneity of the shielding material components. This phenomenon belongs to the structural limitations caused by the dynamic heterogeneity of material viscosity and the spatial uniformity of the shear field in the molding field of plastic materials. The process control unit uses the mixing spindle as a physical transformation unit directly related to the dynamic viscosity characteristics of the multiphase fluid within the mixing chamber. Using the system's electrical signal acquisition module, the real-time torque calibration value of the mixing spindle is periodically acquired at a fixed sampling frequency of 20Hz. The torque transient variability coefficient is calculated using a discrete-time window. The torque transient ripple rate coefficient The calculation formula is: ,in, This is the torque transient ripple rate coefficient. This is the real-time torque calibration value for the mixing spindle. The preset system steady-state constant is 120 N·m. During execution, the process parameter controller simultaneously initiates a dual-track rate-of-change evaluation logic. This logic uses the ratio of the standard deviation to the mean of the torque calculated from 250 consecutive sampling points collected at a 10-m interval as a global statistical indicator of long-term flow trend. The relative deviation rate, established by comparing the current real-time torque value with the aforementioned steady-state constant, serves as the short-term transient rate of change. When the long-term statistical ratio is greater than or equal to 0.40 and the short-term transient relative deviation rate also meets the trigger condition of being greater than or equal to 0.40 for 3.0 seconds, the system confirms that a dense network of unmelted large-sized agglomerates has been constructed within the multiphase fluid, thus triggering... The subsequent deceleration and axial reciprocating pulsation switching actions are used to achieve the fusion and logical normalization of microscopic relative deviation transients and macroscopic statistical trends. The process parameter controller performs continuous division operations between the standard deviation and arithmetic mean of 250 consecutive scalar sampling points to capture long-cycle low-frequency trend characteristics that characterize the macroscopic strain energy of the packing agglomeration network. Simultaneously, the controller extracts the real-time torque calibration value for the current cycle, performs a difference operation with a preset steady-state constant in the register, and then divides by the steady-state constant to extract the short-cycle high-frequency transient rate of change at the microscopic scale. Under this dual-track logic, the control system program uses a logical AND gate to perform a composite judgment of the long-cycle flow trend characteristics and the short-cycle transient rate of change; only... When both values ​​simultaneously cross the quantization threshold of 0.40 and the duration reaches 3.0 seconds, the composite judgment result is mapped and output at the digital logic layer as the final control command that satisfies the first switching boundary condition for the torque transient volatility coefficient. This eliminates measurement noise and reference drift of a single physical dimension in a dynamic heterogeneous flow field. When the calculated torque transient volatility coefficient satisfies the first switching boundary condition of δ-T≥0.40 and the duration of this state reaches 3.0s, the process flow cuts off the current unidirectional steady-state rotational motion, drives the mixing main shaft to switch to the axial pulsating stress penetration stage, monotonically reduces the axial speed to the second shear rate ω-2, and simultaneously sends a drive command to the hydraulic reciprocating drive pump to control the mixing main shaft bearing load of 3.5Hz. The high-frequency hydraulic axial reciprocating pulsating motion has an axial stroke of 15mm. In the actual hardware connection, the mixing spindle is rigidly connected to the output shaft of the main drive reducer through a sliding long spline pair, so that the spindle has the sliding freedom of axial sliding while transmitting high torque rotational power. The axial reciprocating pulsating motion is synchronously driven by two sets of hydraulic servo cylinders symmetrically arranged at the tail of the spindle. The piston rod of the cylinder is connected to the tail end of the spindle through a thrust roller bearing assembly to transmit axial thrust. In order to achieve reliable dynamic sealing under high pressure conditions of multiphase high viscosity melting, the spline output shaft end of the mixing chamber is equipped with three sets of staggered high-temperature resistant polytetrafluoroethylene composite metal skeleton lip seals, and a working pressure of 2 is injected between the seals.A 5 MPa lubricating silicone oil forms a self-compensating mechanical dynamic seal barrier, thereby isolating and eliminating material leakage and bearing vibration under high-frequency, large axial displacement.

[0051] The self-compensating function of the mechanical dynamic sealing barrier is achieved by injecting 2.5 MPa high-pressure lubricating silicone oil to construct a micro-positive pressure hydraulic buffer layer between the three sets of lip seals. The pressure of this buffer layer is always higher than the transient back pressure of the melt inside the mixing chamber, thus physically preventing abrasive, highly conductive powder particles from penetrating to the outside of the sealing interface. At the same time, the staggered composite metal skeleton provides rigid support for the polytetrafluoroethylene lip, enabling it to maintain a tight fit between the lip and the main shaft sliding surface when dealing with the severe axial reciprocating motion at a frequency of 3.5 Hz and a stroke of 15 mm, thanks to the elastic restoring force of the skeleton. Furthermore, the lubricating silicone oil forms a continuous high-temperature lubricating film on the surface of the reciprocating friction pair, limiting the local frictional heat generation within the material's tolerance range and avoiding shear tearing and physical blinding of the sealing material.

[0052] Under the combined flow field of low-speed rotation of the main shaft and high-frequency axial reciprocating pulsation, the steady-state laminar streamlines inside the melt are torn, forming an alternating mechanical stress wave reconstructing a shear network that is propagated at high frequency along the main shaft axis. This asymmetric alternating stress wave acts perpendicularly on the stress defects and weak points at the contact phase interface between the packing particles, and fractally peels off large-sized agglomerates of the packing from the outside to the inside. The rotation of the main shaft follows a discontinuous time sequence of 4.0s working time and 1.5s resting time, and the hydraulic axial reciprocating pulsation action maintains uninterrupted rated high-frequency operation during the 1.5s rotation resting period, utilizing the inherent shear thinning hysteresis of multiphase material fluids. This process allows polymer chain segments to complete stress relaxation and self-heating conduction within a static window free from external rotational flow resistance, thereby controlling the temperature rise rate in the mixing chamber to below 0.3℃ / min. This eliminates the need for secondary mechanical shearing of the dissociated powder filler's aspect ratio by continuous unidirectional shearing, delving into its thermodynamic and physical rheological mechanisms. Although axial reciprocating motion introduces localized axial shearing, the complete cessation of the main rotational movement of the stirring shaft during the 1.5-second rotational static period instantly reduces the overall viscosity heat dissipation caused by strong rotational shearing by over 80%. Simultaneously, the continuous axial reciprocating pulsation induces high-frequency alternating current within the mixing chamber. Axial laminar flow significantly reduces the laminar thermal resistance boundary layer at the inner wall of the cavity, improving the heat transfer coefficient of the high-viscosity melt to the cavity wall with external cooling jacket through forced convection heat transfer. This results in a heat conduction release rate within the stationary window that is much greater than the localized heat generated by weak axial shear, dynamically achieving negative heat growth and precise in-situ temperature control within the global flow field, keeping the cumulative temperature rise rate stable below 0.3℃ / min throughout the entire cycle. As the large-size agglomerated network disintegrates into independent loose particles under axial alternating stress waves, the multiphase fluid tends towards a stable rheological state, while continuously updated transient torque fluctuations... When the rate coefficient satisfies the second switching boundary condition of δ-T≤0.15 and the duration of this state reaches 2.5s, the process control unit terminates the axial reciprocating pulsating motion of the mixing spindle and controls the axial degree of freedom constraint of the spindle to be adjusted to a pure unidirectional rotation state, increasing the mechanical speed to the third shear rate ω-3, where ω-3 is the third shear rate, and its value is constant at 830rpm, thereby transitioning to the high-frequency shear micro-dispersion stage. The dissociated modified multilayer graphene conductive powder particles are driven by a continuous high shear field to exhibit global Brownian diffusion in a low-viscosity pseudoplastic melt. The total duration of this high-frequency shear micro-dispersion stage is limited to 300s.

[0053] When the timer for the high-frequency shear micro-dispersion stage accumulates to 290s, the process control unit initiates the reconstructive timing of the reverse local shear dead zone at the end of the process. By changing the rotation direction of the mixing spindle, the spindle is controlled to rotate in reverse at a speed of 250rpm, generating four rounds of instantaneous reverse alternating motions with a single duration of 0.6s. The momentum impact in alternating directions forces the low-speed laminar flow trajectory of the velocity boundary layer on the inner wall of the mixing chamber to undergo transient detachment and flow reorganization, thereby eliminating laminar adhering particles enriched due to the zero edge velocity gradient and clearing the edge flow dead zone. This is achieved through the timing control logic on the time axis. In the process control unit, the 300-second distributed mixing duration sequence is essentially the net positive convection time accumulated by the controller during unidirectional forward rotation of the spindle. When the positive main timer accumulates to the 290-second boundary point without delay, the control program immediately activates the interrupt mechanism, suspends and pauses the positive main timer in place, and seamlessly switches to the execution of the alternating forward and reverse cycle program. In the extreme long-cycle condition where the duration of a single reverse rotation is 1.5 to 3 seconds, the control system drives the spindle to first perform a reverse rotation for the set lifespan, followed by a forward rotation of equal duration. This constitutes a complete cycle. The alternating forward and reverse cyclic unit is executed continuously four times. During this interruption and reconstruction period, the spindle's forward and reverse tangential change process is accompanied by a 0.2-second motor zero-speed brake transition period. The overall alternating forward and reverse timing consumes a total of 12.8 to 24.8 seconds of independent interrupt time axis. After the four cycles are completely completed and the cavity wall flow dead zone is stripped and reconstructed, the control program cancels the interrupt, wakes up and resumes the execution of the aforementioned suspended forward main timer, driving the spindle to continue to complete the remaining 10 seconds of pure forward high-frequency distributed mixing convection, thereby achieving closed-loop self-consistency in the time axis topology of the entire process and preventing timing overruns. After the reversal and reconstruction sequence is completed, the mixing spindle stops rotating, the process control unit opens the discharge valve at the bottom of the mixing equipment cavity and discharges the mixed multiphase material. The discharged high-speed data cable shielding material has a globally uniformly distributed isotropic conductive topology network inside, with a particle dispersion uniformity coefficient of 0.941, a number-average molecular weight retention rate of the polymer resin matrix of more than 95%, a breaking elongation of 165.7%, and a volume resistivity standard deviation reduced to 0.031 ohm·cm, avoiding high-frequency impedance fluctuations and breakage risks in the finished cable caused by localized agglomeration of fillers.

[0054] Example 2: In the field of high-speed data cable shielding material blending manufacturing process, to verify the practical effectiveness of the method claimed in this invention in dissolving filler agglomerates and protecting matrix polymer chains, the experimental platform was built on a physical experimental device. This physical experimental device is a intensive mixing unit equipped with a hydraulic axial pulsation mechanism, which has a real-time spindle torque measurement resolution of 0.1 N·m, a spindle mechanical speed control accuracy of 1 rpm, and a fluid material temperature sensor monitoring and acquisition frequency of 50 Hz, thereby simulating the shear flow field environment of continuous high-filler blending extrusion molding; in the data acquisition and analysis logic of the experiment, the system acquires the real-time torque calibration value of the stirring spindle. The system determines the data sampling frequency parameter to balance the real-time requirements of capturing transient characteristics of the torque waveform with the filtering and computational load of the process control unit. When the local fluid viscosity fluctuation frequency caused by the spontaneous agglomeration of high surface energy fillers in the mixing chamber is in a high-frequency pulsating state, the data sampling frequency is increased to prevent signal spectrum aliasing under the sampling theorem. Thus, under this decision rule, the sampling frequency of the electrical signal acquisition module is locked at the rated operating frequency of 20Hz for real-time calculation of the torque transient fluctuation rate coefficient. The torque transient ripple rate coefficient The calculation formula is: ,in, This is the torque transient ripple rate coefficient. This is the real-time torque calibration value for the mixing spindle. The system steady-state constant was set at 120 N·m. The experimental setup consisted of a control system comprising the first, second, and third experimental sample groups, a first comparative sample group, a second comparative sample group, a third comparative sample group, and a fourth comparative sample group. Each group used a material system composed of linear low-density polyethylene and 35% by mass of modified multilayer graphene conductive powder. The axial reciprocating pulsation frequencies of the main shafts in the first, second, and third experimental sample groups were set to 2.0 Hz, 3.5 Hz, and 5.0 Hz, respectively, with corresponding axial axial travel distances of 8.0 mm, 11.5 mm, and 15 mm, respectively. 0.0mm; Meanwhile, to verify the multiphase dispersion effect and formulation universality when multiple functional fillers are blended, a fifth experimental sample group was specially set up. The materials put into the mixing chamber were 100% of the total mass of the high-speed data cable shielding material, including 20% ​​carbon nanotubes and 35% conductive carbon black by mass, with the remainder being polyethylene resin as the polymer matrix. This group was operated entirely under the process parameters of the second experimental sample group of this invention. The particle distribution uniformity coefficient of the final shielding material reached 0.939, the number-average molecular weight retention rate of the polymer matrix was 95.8%, the elongation at break of the finished product reached 158.2%, and the standard deviation of volume resistivity was controlled within 0.0 mm. 35 ohm·cm fully demonstrates the homogeneous dissociation and global isotropic dispersion effect of the compound filler system under the action of alternating mechanical stress waves in space; in the actual processing procedure of the fifth test sample group, the process control unit strictly follows the five-stage physical flow field reconstruction control sequence that is completely isomorphic to the second test sample group; in the initial stage, 20% by mass of carbon nanotubes with a diameter of 10nm to 20nm and a length of 5μm to 15μm, and 35% by mass of conductive carbon black with a specific surface area of ​​800m² / g and an oil absorption value of 300ml / 100g, and linear low-density polyethylene particles as the matrix are put into the mixing chamber together; at a speed of 450rpm for convective coarse mixing, high Due to the strong van der Waals forces and the spontaneous interlocking of the highly structured conductive carbon black powder, the carbon nanotubes with a large aspect ratio construct a highly dense composite unmelted large-size particle network inside the melt, causing the real-time torque of the spindle to climb to 185 Nm within 45 seconds after startup. When the first switching boundary condition is triggered, with the transient fluctuation coefficient of the torque greater than or equal to 0.40 and lasting for 3.0 seconds, the system reduces the spindle speed to 200 rpm and superimposes a 3.5 Hz hydraulic axial reciprocating pulsation. At this time, the alternating mechanical stress wave propagating along the axis precisely acts on the entanglement stress defects of the carbon nanotube network, causing the highly entangled tube bundles and carbon black particle clusters to undergo fractal peeling layer by layer from the outside to the inside, and this process is repeated after 4.0 seconds of operation and 1 second of rest.A 5-second intermittent cycle allows the long polymer chains to relax in situ; subsequently, a high-frequency distributed mixing stage at 830 rpm is initiated, where the dissociated fine conductive particle stream exhibits Brownian diffusion. Finally, at the end of the process, four alternating forward and reverse impacts at 250 rpm clear the dead zones in the cavity walls, forming an interpenetrating isotropic double-conductive topology network. The first comparative sample group did not undergo axial reciprocating pulsation of the main shaft, and the remaining process timing parameters were consistent with the second experimental sample group of this invention. The axial reciprocating pulsation frequency of the main shaft in the second comparative sample group was set to 1.2 Hz, and the axial axial displacement was set to 5.0 mm. The axial reciprocating pulsation frequency of the main shaft in the third comparative sample group was set to 6.2 Hz, and the axial axial displacement was set to 20.0 mm. The fourth comparative sample group employed a unidirectional continuous constant shearing process, maintaining a constant axial rotation speed of 450 rpm, and did not undergo axial reciprocating pulsation of the main shaft.

[0055] During the blending process, Gaussian white noise with a signal-to-noise ratio of 15dB exists in the signal stream of the spindle torque sensor, and alternating temperature disturbances exist in the external heat transfer channels of the mixing chamber. During the initial low-speed convection coarse mixing operation, the resistance generated by the melt wetting of the multiphase fluid affects the real-time torque calibration values ​​of each group. All show a monotonically increasing trend, when the calculated torque transient variability coefficient satisfies Furthermore, when the duration of this state reaches the first switching boundary condition of 3.0s, the process flow cuts off the unidirectional steady-state rotational motion, drives the mixing main axis to switch to the axial pulsating stress penetration stage, and monotonically reduces the axial speed to the second shear rate. The system synchronously sends drive commands to the hydraulic reciprocating drive pump to control the axial reciprocating pulsation of the mixing main bearing at 3.5 Hz, with an axial lateral stroke of 15 mm. When the main shaft speed decreases to 200 rpm and the axial reciprocating pulsation of the main shaft is superimposed, the torque transient fluctuation coefficient of the second test sample group of the present invention decreases, and the temperature rise rate inside the mixing chamber measured by the temperature sensor remains at 0.23℃ / min during the 1.5s rotational rest period. The temperature rise rate inside the mixing chamber of the fourth comparative sample group remains at 2.64℃ / min, causing thermomechanical chain breakage in the polymer resin matrix. The velocity boundary layer on the inner wall of the mixing chamber of the first comparative sample group causes flow stagnation and fails to eliminate packing agglomeration. In the third comparative sample group, the aspect ratio topology of the modified multilayer graphene conductive powder underwent mechanical severing; in the second comparative sample group, due to the shear stress amplitude of the alternating mechanical stress wave being lower than the yield stress of the agglomerate, its torque transient fluctuation coefficient continuously oscillated at a level of 0.38. After the multiphase mixing process was completed, the system discharged each group of high-speed data line shielding material finished products from the bottom of the mixing equipment cavity. Among them, the second experimental sample group of the present invention, which adopted the technical solution of the present invention, had a particle distribution uniformity coefficient of 0.943, a number-average molecular weight retention rate of 96.28% for the polymer resin matrix, a breaking elongation of 165.9% for the shielding material finished product, and a volume resistivity of 0.943. The standard deviation was 0.032 Ω·cm; the particle distribution uniformity coefficient of the first test sample group of the present invention was 0.912, the number-average molecular weight retention rate was 95.42%, the elongation at break was 153.4%, and the standard deviation of volume resistivity was 0.048 Ω·cm; the particle distribution uniformity coefficient of the third test sample group of the present invention was 0.938, the number-average molecular weight retention rate was 95.14%, the elongation at break was 151.2%, and the standard deviation of volume resistivity was 0.039 Ω·cm; the particle distribution uniformity coefficient of the first control sample group was 0.732, the number-average molecular weight retention rate was 88.54%, the elongation at break was 138.6%, and the standard deviation of volume resistivity was 0. The first control group had a particle distribution uniformity coefficient of 186 Ω·cm; the second control group had a particle distribution uniformity coefficient of 0.704, a number-average molecular weight retention rate of 89.12%, an elongation at break of 140.3%, and a volume resistivity standard deviation of 0.205 Ω·cm; the third control group had a particle distribution uniformity coefficient of 0.815, a number-average molecular weight retention rate of 76.81%, an elongation at break of 131.6%, and a volume resistivity standard deviation of 0.142 Ω·cm; the fourth control group had a particle distribution uniformity coefficient of 0.675, a number-average molecular weight retention rate of 71.38%, an elongation at break of 120.2%, and a volume resistivity standard deviation of 0.426 Ω·cm.

[0056] The quantitative results obtained from the comparison of the above multiple sample tests show that the torque transient fluctuation rate coefficient calculated by solving the single torque time series of the stirring spindle is... Used as a criterion to guide the flow field transition in the blending molding process, and with the intermittent time coordination of the low-speed rotation of the main shaft and the high-frequency mechanical pulsation of the axial direction, an isotropic conductive network is constructed in the molding cavity. This flow field reconstruction directly addresses the technical problems of component segregation and shear heating chain breakage in highly filled multiphase materials. This allows the shielding material to maintain high elongation at break and mechanical toughness while reducing the spatial deviation of volume resistivity, thereby smoothing high-frequency impedance fluctuations and multi-point signal leakage in the transmission of high-speed data cables.

[0057] Example 3: When multiple sets of temperature-controlled blending extrusion systems are used to perform high-performance, high-speed data line shielding material blending flow field molding, due to the flow instability of multiple batches of polyolefin macromolecular chain base material and inorganic functional particle fluid in the early stage of melting, the initial viscosity reference of the melt inside the mixing chamber is uncontrolled due to the batch fluctuation of raw materials. This causes a mismatch between the fixed static control parameters and the floating operating flow resistance, and causes the torque reference of the stirring spindle to deviate or the axial stress penetration timing to lag. This makes the highly filled phase melt unable to adaptively adjust the flow field energy input when facing a sudden large amount of filler agglomeration network, causing strong mechanical friction heating in situ to degrade the matrix molecular skeleton or leave a large number of unsheared local dead zone particle clusters. This phenomenon belongs to the engineering application challenges caused by the variation of the physical boundary of raw materials and the rigid limitation of the static control system in the molding and processing of plastic materials.

[0058] The digital control chip establishes a material physical specification locking and offline rheological grade difference parameter adaptive calibration procedure to eliminate the aforementioned reference drift. The polymer resin matrix is ​​limited to linear low-density polyethylene (LLDPE), with the LLDPE melt index measured according to national standard testing methods at 190℃ and 2.16kg load, ranging from 0.8g / 10min to 1.2g / 10min. The conductive filler is limited to modified multilayer graphene conductive powder with an average transverse dimension of 5.0μm to 8.0μm and a specific surface area of ​​60m² / g to 80m² / g. This locks the input property reference. When calibrating the control threshold, the process control unit operates in a steady-state environment where the mixing chamber temperature is maintained at 180℃. The electric drive device drives the mixing spindle to rotate the components in the mixing chamber unidirectionally in the forward direction, running the LLDPE at an initial speed of 450rpm until a stable rheological state is reached. The average torque waveform of the mixing spindle at this point is measured to be 120N·m, and this average value is locked as the rated torque reference value. In this constant flow field, modified multilayer graphene conductive powder is added in a gradient of 5 wt% per minute until the inorganic particles in the material system form a large-size dense agglomeration network due to high surface energy and undergo localized shear stress concentration and dissipation. This corresponds to capturing the inflection point of the transient torque jump caused by the sudden change in fluid rheological viscosity resistance at this time, which is 1.40 times the scalar level of the initial calibration mean, thereby determining the transient torque fluctuation coefficient. The calculation formula is as follows: ,in, This is the torque transient ripple rate coefficient. This is the real-time torque calibration value for the mixing spindle. The preset system steady-state constant is a constant value of 120 N·m. Simultaneously, to filter out non-stationary Gaussian random noise generated by high-frequency industrial mechanical vibration and stray currents, the electrical signal acquisition module, after acquiring the raw voltage signal from the torque sensor, inputs the acquired continuous-time discrete sequence data stream into a sliding time window. The sliding time window length is set to 60 sampling points. Internally, the microprocessor calculates the sliding arithmetic mean of the discrete scalar values ​​within the window in real time, smooths out noise components, and continuously outputs the real-time torque calibration value. As a clean independent variable input for subsequent logic switching control loops.

[0059] The continuous supply of clean independent variable sequence data drives the process control unit to solve the current torque transient deviation state under abnormal interference in the online flow field. When the flow field temperature or resin viscosity experiences a small baseline drift due to external disturbances, the sliding time window continuously offsets data noise. When the filtered value is greater than or equal to 0.40 and this state is continuously maintained for 3.0s under the first switching boundary condition of 20Hz discrete sampling sequence, the microprocessor issues a step command to reduce the mechanical speed to 200rpm and simultaneously starts the hydraulic reciprocating drive pump to apply 3.5Hz axial reciprocating pulsation action, so that the polymer chain skeleton obtains flow stress relaxation space and forces the dense network to disintegrate layer by layer from the outside to the inside. After the high-speed data line shielding material is mixed, a uniformly distributed isotropic conductive topology network is constructed inside, which limits the laminar flow adhesion particles and flow retention blind areas on the wall surface, and maintains the stability of volume resistivity and high elongation mechanical toughness.

[0060] Example 4: When assembling equipment or replacing mixing components, based on the differences in mechanical stress between different machines and the physical environment of inherent frictional fluctuations in the spindle bearings, the control chip drives the mixing spindle to run at an initial speed of 450 rpm for 600 seconds under no-load before feeding materials into the mixing chamber. This utilizes the frictional heating of the velocity boundary layer within the chamber to raise the inner wall temperature to the set processing temperature of 180°C. The electrical signal acquisition module collects 1200 discrete torque values ​​at a sampling frequency of 20 Hz and inputs them into the buffer. The process control unit removes the first 200 transient noise points generated during startup and calculates the arithmetic mean of the remaining 1000 stable values ​​to determine the no-load resistance torque. .

[0061] The process control unit introduces unfilled polyethylene resin base material into the mixing chamber. While maintaining a constant temperature flow field of 180°C, the mixing spindle is controlled to flow at an initial speed of 450 rpm. When the variance change rate of the torque sliding mean waveform is less than 0.05, the process control unit obtains the pure-phase shear resistance torque. Calculate the system steady-state constant according to the following formula. ,in, Let be the system steady-state constant. For pure-phase shear resistance torque, For the no-load resistance torque, the microprocessor writes the calculation results into the register to participate in the calculation of the torque transient fluctuation coefficient δ-T under high filling conditions, eliminates the threshold deviation caused by assembly friction loss, controls the timing of the reduction of the mixing spindle speed and the fractal peeling of the packing network in response to the axial reciprocating pulsating action, and keeps the particle distribution uniformity coefficient inside the finished high-speed data line shielding material above 0.940.

[0062] Example 5: When multiple parallel units implement high-performance high-speed data line shielding material blending flow field distribution and the mechanical components inside the mixing chamber undergo physical wear due to long-term operation, the assembly gap between the stirring spindle inside each discrete production line and the wall lining of the mixing chamber undergoes a gradual monotonically increasing change. This in-situ slippage of geometric dimensions changes the spatial distribution of the tangential viscous resistance field inside the mixing flow field, causing the real-time torque calibration value obtained by the electrical signal acquisition module to drift slowly in the same direction. If the process control unit still uses the fixed first switching state judgment rule to identify the large-size agglomeration network of modified multilayer graphene conductive powder, it will cause a delay in the response time of the flow field shear control sequence, which in turn accumulates overloaded viscous heat dissipation inside the highly filled plastic melt, destroys the aspect ratio topological skeleton of the functional filler and causes the molecular chain of linear low-density polyethylene to break and deteriorate. This rheological resistance reference drift belongs to the dynamic system mismatch control challenge caused by machine wear in the molding field of plastic state materials.

[0063] The process control unit operates an adaptive parameter matrix calibration procedure based on mechanical backlash detection and adaptive threshold correction, periodically reading the measured residual mechanical backlash value between the spindle and the cavity wall through a displacement detection sensor. And call the following regarding the clearance wear compensation coefficient inside the microprocessor. The calculation formula updates the system control parameters: From the analysis of the rheological shear stress distribution mechanism, the tangential shear rate borne by the melt in the mixing chamber is inversely proportional to the size of the geometric gap between the main shaft and the chamber wall. When the residual gap increases due to long-term wear of the mixing components, the actual shear stress inside the flow field at a constant speed decreases monotonically, which leads to a synchronous proportional decay of the shear flow resistance torque fed back by the stirring main shaft. Therefore, this invention establishes the ratio between the standard nominal gap value and the measured residual gap value, and reconstructs the shear rate decay coefficient from the dimension of physical structure change. By multiplying this wear compensation coefficient with the preset system steady-state constant, the shear resistance measurement benchmark lost due to the expansion of the geometric gap can be accurately offset, so that the corrected rated torque benchmark calibration value truly reflects the fluid resistance jump inflection point under the current wear condition. ,in, This is the clearance wear compensation coefficient. The preset standard nominal clearance value is constant at 1.0 mm. To obtain the measured mechanical residual clearance value, the clearance wear compensation coefficient was calculated. Used for the reference value of rated torque Make corrections to produce the corrected rated torque reference calibration value. Its update formula is as follows: ,in, This is the corrected reference calibration value for the rated torque. The system steady-state constant is a preset value of 120 N·m; To compensate for the wear gap, in the specific hardware deployment, the aforementioned displacement detection sensor is a non-contact, high-precision eddy current sensor installed on the outside of the mixing chamber. Its probe focuses on the outer circular surface of the non-working shoulder of the mixing spindle through a ceramic insulated and sealed window with good thermal conductivity and pressure resistance, pre-reserved on the chamber wall. Since the eddy current sensor uses the eddy current changes induced by a high-frequency electromagnetic field on the surface of the metal spindle to measure micrometer-level distances, its measurement signal can completely penetrate the barrier layer formed by the internal plastic melt and highly conductive graphene filler, and is unaffected by the high temperature of 180°C and the opacity of the multiphase fluid within the mixing chamber. Therefore, it can accurately lock and continuously output the mechanical residual clearance value caused by the displacement variation of the spindle due to physical wear at a data update frequency of 50 times per second. In actual measurement mapping, there is a difference between the mechanical displacement of the non-working shoulder and the actual physical wear clearance at the tip of the screw thread inside the mixing chamber. The established rigid kinematic transmission relationship, through pre-inputting a geometric mapping matrix based on the thermal expansion coefficient of the intensive mixer casing and the axial positioning stiffness of the main shaft bearing into the digital control chip, can transform the macroscopic displacement variable of the non-working shoulder into the microscopic clearance change of the material shear zone inside the cavity. Furthermore, this adaptive parameter matrix calibration procedure utilizes tangential viscous resistance field data of multiphase fluids under different wear gradients to construct a discrete correspondence between the mechanical residual clearance and the attenuation ratio of the main shaft shear resistance torque. This ensures that every 0.01 mm axial displacement change captured by external sensors can be accurately mapped to the micrometer-level wear thickness change on the surface of internal components caused by material friction, eliminating cross-scale measurement errors between external mechanical displacement and actual internal physical wear. This parameter reconstruction calculation compensates for torque deviations caused by assembly wear in real time to the torque transient fluctuation coefficient. In the denominator, the process control chip is able to capture the sudden inflection point of multiphase fluid rheological resistance and complete the response switching of shear control timing even under deviation conditions where the gap is expanded to 1.8mm and the corresponding flow resistance torque decreases by 15%.

[0064] After the parameters of each parallel unit in the cluster are corrected using the aforementioned adaptive parameter matrix calibration procedure, the microprocessors of each group are calibrated according to the updated rated torque reference value. Real-time calculation of torque transient ripple coefficient This allows the flow field adjustment action to avoid time delay interference, driving the mixing spindle to monotonically decrease in speed to 200 rpm and superimposing a 3.5 Hz axial reciprocating pulsation action to transmit alternating mechanical stress waves. By implementing spatial retreat of the mechanical kinetic energy of the flow field at the critical point of shear heat accumulation, each mixing unit discharges material after the process cycle ends. The discharged high-speed data line shielding material finished product has a globally uniformly distributed isotropic conductive topology network inside, with a particle distribution uniformity coefficient of 0.945. The number average molecular weight retention rate of the polymer resin matrix is ​​greater than 96.1%, and the elongation at break of the finished product is at 166.3%. Moreover, the spatial standard deviation of the volume resistivity of the shielding material semi-finished products between each production line is reduced to below 0.030 Ω·cm, controlling the risk of flow field distortion and quality heterogeneity caused by mechanical wear and tear of single-unit assembly.

[0065] The above description is merely a selection of preferred embodiments of this disclosure and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in the embodiments of this disclosure is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the above-described inventive concept. For example, technical solutions formed by substituting the above-described features with (but not limited to) technical features with similar functions disclosed in the embodiments of this disclosure.

Claims

1. A mixing process for a high-speed data cable shielding material, characterized in that, include: Step S1: The polymer resin matrix and conductive filler are put into the mixing chamber; Step S2: Drive the mixing spindle to rotate the components in the mixing chamber in the forward direction, perform convective coarse mixing at an initial speed of 450 rpm, and collect the real-time torque value of the mixing spindle. Step S3: Calculate the torque transient fluctuation coefficient based on the comparison result between the real-time torque value and the preset rated torque reference value; when the torque transient fluctuation coefficient is greater than or equal to 0.40 and lasts for 3.0s, reduce the rotational speed of the mixing spindle to 200rpm, and control the mixing spindle to perform axial reciprocating motion with a frequency of 3.5Hz and a reciprocating displacement of 15mm; simultaneously control the rotational operation of the mixing spindle to follow an alternating time cycle of 4.0s working and 1.5s resting, and maintain the axial reciprocating motion during the resting period; Step S4: Continuously update the torque transient fluctuation rate coefficient. When the torque transient fluctuation rate coefficient is less than or equal to 0.15 and lasts for 2.5s, terminate the axial reciprocating motion and increase the rotational speed of the mixing spindle to 830rpm for distributed mixing. The duration of the distributed mixing is 300s. Step S5: When the distribution mixing has been performed for 290 seconds, the rotation direction of the mixing spindle is changed, and the mixing spindle is controlled to perform 4 alternating forward and reverse cycles at a speed of 250 rpm.

2. The mixing process of a high-speed data cable shielding material according to claim 1, characterized in that, In step S2, the axial reciprocating motion and the rotational motion of the mixing spindle together induce a complex flow in the mixing chamber, generating a gradient flow field shear velocity in the axial space of the mixing chamber, causing the locally agglomerated particles of the conductive filler to disperse into loose particles under the action of the alternating stress.

3. The mixing process of a high-speed data cable shielding material according to claim 1, characterized in that, In step S3, the alternating timing cycle is repeated 10 to 15 times. During the stationary period of the rotating operation of the mixing spindle, the axial reciprocating pulsation frequency of the mixing spindle is controlled by the axial pulsation drive mechanism to be 2 Hz to 5 Hz, and the axial reciprocating displacement is 8 mm to 15 mm. The axial shear laminar flow caused by the axial reciprocating motion reduces the accumulation of internal heat energy in the mixing chamber and controls the temperature rise rate in the mixing chamber to be less than 0.3 ℃ / min.

4. The mixing process of a high-speed data cable shielding material according to claim 1, characterized in that, In step S3, the calculation procedure for the torque transient fluctuation coefficient is as follows: the process parameter controller collects the real-time torque data of the mixing spindle at a sampling period of 10ms, and calculates the ratio of the standard deviation to the mean of the torque within 250 consecutive sampling points, and determines the ratio as the torque transient fluctuation coefficient.

5. The mixing process of a high-speed data cable shielding material according to claim 1, characterized in that, Step S4 includes the following sub-steps: Step S41: Control the mixing spindle to run at a speed of 830 rpm for 200 seconds to break the residual network of the conductive filler. Step S42: Control the mixing spindle to maintain its rotation speed for the next 100 seconds, drive the dispersed conductive filler to flow and convect within the polymer resin matrix, and complete the homogenization distribution of the mixed material.

6. The mixing process of a high-speed data cable shielding material according to claim 1, characterized in that, The material fed into the mixing chamber comprises 100% of the total mass of the high-speed data line shielding material, 15% to 25% of the mass of carbon nanotubes, 30% to 40% of the mass of conductive carbon black, and the remainder is polyethylene resin as the polymer resin matrix.

7. The mixing process of a high-speed data cable shielding material according to claim 1, characterized in that, In step S5, the process parameter controller switches the rotation direction of the mixing spindle and controls the mixing spindle to run at a reverse speed of 250 rpm. The duration of a single reverse rotation is 1.5 s to 3 s, and the forward and reverse rotation cycles are repeated 4 times.

8. The mixing process of a high-speed data cable shielding material according to claim 1, characterized in that, The polymer resin matrix is ​​linear low-density polyethylene, which has a melt index of 0.8 g / 10 min to 1.2 g / 10 min and a density of 0.918 g / cm³ to 0.922 g / cm³ at 190°C and a load of 2.16 kg.

9. The mixing process of a high-speed data cable shielding material according to claim 1, characterized in that, After step S5 is completed, the elongation at break of the finished high-speed data line shielding material is not less than 150%, and the volume resistivity is not higher than 10 Ω·cm.

Images