Anti-corrosion electronic wire

Abstract

The utility model relates to the technical field of electronic wires, in particular to an anti-corrosion electronic wire which comprises a battery core conductor, a spiral groove is arranged on the outer side surface of the battery core conductor, conductive gel containing benzotriazole is filled in the spiral groove, a conductive layer is sleeved on the outer side of the battery core conductor, a chemical passivation layer is arranged on the outer side of the conductive layer, and an anti-corrosion layer is arranged on the outer side of the chemical passivation layer. The outer side of the chemical passivation layer is sleeved with a physical blocking layer, the outer side of the physical blocking layer is provided with a fireproof mica layer, the outer side of the fireproof mica layer is sleeved with a shielding layer, the outer side of the shielding layer is sleeved with an armor layer, and the outer side of the armor layer is sleeved with an anti-corrosion sheath. Through the synergistic effect of the chemical passivation layer and the four-layer composite anti-corrosion sheath (the W61-3 organic silicon coating, the graphene epoxy coating, the nano modified layer and the PTFE glass fiber composite layer), a chemical and physical dual protection system is formed, the cable can resist complex corrosion environments such as acid, alkali, salt and humid and hot atmosphere, and the protection life is prolonged by more than three times.

Description

TECHNICAL FIELD

[0001] The utility model relates to electronic wire technical field especially relates to a kind of anticorrosive electronic wire. BACKGROUND

[0002] In the field of industrial automation, ocean engineering, chemical equipment and new energy, electronic cable is exposed to high humidity, salt spray, acid and alkali corrosion or high temperature for a long time, which is easy to cause corrosion, oxidation or mechanical damage, leading to the decrease of conductive performance, insulation failure and even short circuit, seriously affecting the safety and service life of equipment. The conventional anticorrosive electronic cable mainly adopts the following technical scheme: single-layer anticorrosive sheath, such as polyvinyl chloride (PVC) or polyethylene (PE) sheath, which has certain corrosion resistance, but is easy to age and crack under the long-term action of strong corrosive medium (such as acid, alkali and salt spray), leading to the failure of protection,

[0003] The existing technology has the following disadvantages: single corrosion resistance: only relying on physical barrier or chemical passivation, unable to cope with complex corrosion environment; flexibility and protection contradiction: armored layer is too thick, which reduces the bending performance, and too thin, which is not enough for mechanical protection; poor long-term stability: traditional sheath is easy to age under the action of long-term heat and humidity, ultraviolet rays or chemical medium, leading to the failure of protective layer; lack of self-repairing mechanism: corrosion medium directly enters the conductor after the damage of sheath, accelerating the damage of cable. Therefore, an anticorrosive electronic wire is proposed. UTILITY MODEL CONTENT

[0004] The utility model discloses in order to solve the shortcomings in the prior art, and propose an anticorrosive electronic wire.

[0005] In order to achieve the above purpose, the utility model adopts the following technical scheme:

[0006] An anticorrosive electronic wire includes an electric core conductor, a spiral groove is arranged on the outer surface of the electric core conductor, a conductive gel containing benzotriazole is filled in the spiral groove, a conductive layer is sleeved on the outer side of the electric core conductor, a chemical passivation layer is arranged on the outer side of the conductive layer, a physical barrier layer is sleeved on the outer side of the chemical passivation layer, a fire-resistant mica layer is arranged on the outer side of the physical barrier layer, a shielding layer is sleeved on the outer side of the fire-resistant mica layer, an armored layer is sleeved on the outer side of the shielding layer, and an anticorrosive sheath is sleeved on the outer side of the armored layer.

[0007] Preferably, the depth of the spiral groove is 50-200 μm.

[0008] Preferably, the shielding layer is an aluminum foil member with a thickness of 0.1-0.3 mm.

[0009] As preferred, the armored layer is in segmented armor, with hard corrosion-resistant alloy pieces (2-5 mm in length) alternating with flexible silicone segments, and the bending radius can be reduced to 3D (D is the diameter of the wire).

[0010] As preferred, the corrosion-resistant sheath is sequentially provided with corrosion-resistant layer one, corrosion-resistant layer two, corrosion-resistant layer three, and corrosion-resistant layer four from inside to outside.

[0011] As preferred, the corrosion-resistant layer one is a W61-3 silicone coating layer, the corrosion-resistant layer two is a graphene composite epoxy coating layer, the corrosion-resistant layer three is a nano filler modified corrosion-resistant layer, and the corrosion-resistant layer four is a polytetrafluoroethylene (PTFE) and glass fiber composite outer skin member.

[0012] As preferred, a self-repairing intermediate layer is provided between the armored layer and the corrosion-resistant sheath, and the self-repairing intermediate layer is filled with microencapsulated corrosion inhibitors.

[0013] In summary, the utility model has long-term corrosion resistance: through the synergistic effect of the chemical passivation layer and the four-layer composite corrosion-resistant sheath (W61-3 silicone coating, graphene epoxy coating, nano modified layer, PTFE glass fiber composite layer), a chemical + physical double protection system is formed, which can resist complex corrosion environments such as acid, alkali, salt, and humid atmosphere, and the protection life is increased by more than 3 times.

[0014] The utility model, through the microencapsulated corrosion inhibitor of the self-repairing intermediate layer, can automatically release the repair agent when the sheath is damaged, realizing the local corrosion protection self-repairing function.

[0015] The utility model improves the conductivity stability: the spiral groove design (depth 50-200 μm) cooperates with the benzotriazole-containing conductive gel, which not only increases the conductor surface area to reduce resistance, but also inhibits electrochemical corrosion through benzotriazole, so that the resistance fluctuation rate of the cable in a humid environment is reduced to within ±1.5%.

[0016] The utility model enhances the mechanical environmental adaptability: the segmented armored layer alternately arranges hard alloy pieces and silicone segments, taking into account impact resistance and flexibility, and the bending radius can be reduced to 3D, suitable for dynamic wiring scenarios.

[0017] The utility model combines the fire-resistant mica layer and the aluminum foil shielding layer, which can still maintain insulation performance for 30 minutes at 800℃ high temperature, and provides electromagnetic shielding effectiveness of more than 60 dB.

[0018] The utility model has structural synergy advantages: the physical barrier layer and the chemical passivation layer form active passivation + passive isolation double protection, which can reduce 70% of corrosion medium penetration compared with a single protective layer.

[0019] This invention employs a four-layer differentiated anti-corrosion sheath with a material gradient design (organosilicon → graphene → nanofiller → PTFE) to achieve an optimized distribution of increasing hardness and decreasing porosity from the inside out, resulting in an overall salt spray resistance performance exceeding 5000 hours. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the cross-section of this utility model.

[0021] In the diagram: 1. Battery core conductor; 2. Conductive layer; 3. Chemical passivation layer; 4. Physical barrier layer; 5. Fire-resistant mica layer; 6. Shielding layer; 7. Armor layer; 8. Anti-corrosion sheath; 81. Anti-corrosion layer one; 82. Anti-corrosion layer two; 83. Anti-corrosion layer three; 84. Anti-corrosion layer four. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0023] like Figure 1 As shown, a corrosion-resistant electronic wire includes a conductor core 1. The conductor core 1 is made of high-purity oxygen-free copper with a purity ≥99.99% or tin-plated copper wire to improve conductivity and oxidation resistance. Spiral grooves are machined on the outer surface of the conductor 1, with a groove depth of 50-200 μm and a pitch of 1.2-2 times the conductor diameter, to increase the conductor surface area and reduce resistance.

[0024] The spiral grooves are filled with a benzotriazole-containing conductive gel. This gel consists of 15%-30% silver powder / carbon nanotube conductive filler, 0.5%-2% benzotriazole corrosion inhibitor, and a silicon-based gel carrier. It can inhibit electrochemical corrosion in humid environments while maintaining low contact resistance.

[0025] The conductive layer 2 is made of silver-plated copper braided layer with a coverage of ≥90% to enhance electromagnetic compatibility;

[0026] The chemical passivation layer 3 is a molybdate conversion coating, which is formed by impregnation or spraying process and has a thickness of 5-10 μm, which can effectively inhibit the electrochemical corrosion of the metal layer;

[0027] The physical barrier layer 4 is made of polyimide (PI) film with a thickness of 25-50 μm, which has excellent high temperature resistance and barrier properties.

[0028] The fire-resistant mica layer 5 uses synthetic mica tape with glass fiber cloth as the base material and mica sheets coated on both sides. It can maintain its insulation performance for 30 minutes at 800℃.

[0029] The shielding layer 6 uses an aluminum foil wrapping + tin-plated copper wire braided layer. The aluminum foil thickness is 0.1-0.3mm, the braiding density is ≥85%, and it provides an electromagnetic shielding effectiveness of ≥60dB.

[0030] The armor layer 7 adopts a segmented structure, consisting of alternating hard anti-corrosion alloy sheets with a length of 2-5mm and flexible silicone segments. The alloy sheets are made of 316L stainless steel or Hastelloy, and the silicone segments have a hardness of Shore A 40-60, which reduces the cable bending radius to 3DD wire diameter, making it suitable for dynamic cabling scenarios.

[0031] The corrosion-resistant sheath 8 adopts a four-layer composite structure, which consists of the following layers from the inside out:

[0032] Anti-corrosion layer 1: W61-3 silicone coating, thickness 50-100μm, temperature range -60℃-250℃, provides basic anti-corrosion and heat resistance;

[0033] Anti-corrosion layer 2 82: Graphene composite epoxy coating, with a graphene content of 1% to 3% and a thickness of 80 to 150 μm, enhances impermeability and mechanical strength;

[0034] Anti-corrosion layer 383: Nanofiller modified anti-corrosion layer, using SiO2 / TiO2 nanoparticles dispersed in a polyurethane matrix, with a thickness of 100-200μm, which can effectively block the diffusion of corrosive media;

[0035] Anti-corrosion layer 484: PTFE and glass fiber composite outer skin, thickness 0.3~0.5mm, surface friction coefficient ≤0.1, with wear resistance, chemical corrosion resistance and anti-adhesion properties.

[0036] A self-healing intermediate layer is set between the armor layer 7 and the anti-corrosion sheath 8. The intermediate layer is filled with microencapsulated corrosion inhibitor with a particle size of 20-50μm. The shell material is urea-formaldehyde resin and the core material is benzotriazole derivative. When the sheath is damaged, the microcapsules rupture and release the corrosion inhibitor, forming a protective film at the damaged site and slowing down the corrosion process.

[0037] In this embodiment, the conductor processing involves forming spiral grooves on the surface of a copper conductor through precision rolling and filling them with conductive gel.

[0038] Multi-layer coating: sequentially coated with conductive layer 2, chemical passivation layer 3, physical barrier layer 4, mica layer 5, and shielding layer 6;

[0039] Armor layer molding: The segmented armor layer 7 is injection molded using a mold, with alternating hard alloy sheets and silicone segments;

[0040] Sheath extrusion: Four layers of anti-corrosion sheath 8 are formed sequentially through co-extrusion process, and a self-healing intermediate layer is coated between the armor layer and the sheath;

[0041] Post-processing: The cable is cured with ultraviolet light or baked with heat to ensure a strong bond between the layers.

[0042] Performance testing in this embodiment:

[0043] Salt spray test: Tested according to GB / T 10125 standard, no corrosion perforation after 5000 hours.

[0044] Bending life: In a ±180° bending test, the resistance change rate is ≤2% after 5000 cycles.

[0045] Self-healing verification: After the sheath is artificially scratched, the corrosion inhibitor can effectively inhibit the corrosion of the substrate within 72 hours.

[0046] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A corrosion-resistant electronic wire, characterized in that, The device includes a battery core conductor (1), the outer surface of which is provided with a spiral groove, the spiral groove is filled with a conductive gel containing benzotriazole, a conductive layer (2) is sleeved on the outer side of the battery core conductor (1), a chemical passivation layer (3) is provided on the outer side of the conductive layer (2), a physical barrier layer (4) is sleeved on the outer side of the chemical passivation layer (3), a fire-resistant mica layer (5) is provided on the outer side of the physical barrier layer (4), a shielding layer (6) is sleeved on the outer side of the fire-resistant mica layer (5), an armor layer (7) is sleeved on the outer side of the shielding layer (6), and an anti-corrosion sheath (8) is sleeved on the outer side of the armor layer (7).

2. The corrosion-resistant electronic wire according to claim 1, characterized in that, The depth of the spiral groove is 50-200 μm.

3. The corrosion-resistant electronic wire according to claim 1, characterized in that, The shielding layer (6) is made of aluminum foil with a thickness of 0.1-0.3 mm.

4. The corrosion-resistant electronic wire according to claim 1, characterized in that, The armor layer (7) is a segmented armor, with hard anti-corrosion alloy sheets (2-5mm in length) and flexible silicone segments arranged alternately, and the bending radius can be reduced to 3D (D is the wire diameter).

5. The corrosion-resistant electronic wire according to claim 1, characterized in that, The anti-corrosion sleeve (8) is configured as anti-corrosion layer one (81), anti-corrosion layer two (82), anti-corrosion layer three (83), and anti-corrosion layer four (84) from the inside out.

6. The corrosion-resistant electronic wire according to claim 5, characterized in that, The first anti-corrosion layer (81) is coated with W61-3 silicone coating, the second anti-corrosion layer (82) is coated with graphene composite epoxy coating, the third anti-corrosion layer (83) is a nanofiller modified anti-corrosion layer, and the fourth anti-corrosion layer (84) is a composite outer skin component of polytetrafluoroethylene (PTFE) and glass fiber.

7. The corrosion-resistant electronic wire according to claim 1, characterized in that, A self-healing intermediate layer is provided between the armor layer (7) and the anti-corrosion sheath (8), and the self-healing intermediate layer is filled with microencapsulated corrosion inhibitor.

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