High-temperature-resistant flame-retardant power cable applied to robot

Abstract

The utility model belongs to the field of robot power cables, and provides a high-temperature-resistant flame-retardant power cable applied to a robot, which comprises a plurality of conductor layers and insulating layers, each conductor layer is coated with one insulating layer, the insulating layers are made of polytetrafluoroethylene materials, and the insulating layers and the conductor layers jointly form insulating wire cores. A plurality of insulating wire cores are twisted into a cable core through a filling layer; and the polyester layer and the low-smoke halogen-free flame-retardant belt are sequentially wrapped outside the cable core and are used for isolating the insulating layer. Compared with the prior art, the utility model has the advantages that the polytetrafluoroethylene is used as an insulating material, so that the dielectric strength and the dielectric loss stability at high temperature are improved; and the sheath layer adopts a halogen-free flame-retardant polyether-ether-ketone and polytetrafluoroethylene blended material, and ceramic silicone rubber is combined, so that a gas-phase and solid-phase dual flame-retardant mechanism is realized, the power cable can still keep the characteristics of high temperature resistance and high flame retardance in a high-temperature environment, and the service life is prolonged.

Description

Technical Field

[0001] This utility model belongs to the field of robot power cables, specifically relating to a high-temperature resistant and flame-retardant power cable for use in robots. Background Technology

[0002] In modern industrial production environments, especially in applications involving robots and automated production lines, the performance requirements for cables are becoming increasingly stringent. Due to limitations in their materials and structure, traditional robot cables are prone to insulation aging and conductor oxidation in high-temperature environments. These problems can lead to increased resistance or even short circuits, affecting the normal operation of the robot and potentially causing safety accidents.

[0003] To achieve flame-retardant effects, ordinary flame-retardant cables typically use halogen-containing flame retardants (such as PVC). However, these materials release toxic gases when burning, posing a threat to the environment and human health. On the other hand, mica-wrapped cables have excellent flame-retardant properties, but their poor flexibility makes them unsuitable for applications requiring frequent bending. While halogen flame-retardant materials can provide some fire protection, their temperature resistance is usually limited to no more than 150°C, failing to meet the requirements of high-temperature applications. Utility Model Content

[0004] The purpose of this invention is to address the aforementioned problems in the existing technology by proposing a high-temperature resistant and flame-retardant power cable for use in robots that has a simple structure and can maintain high durability, high flame retardancy, and stable electrical performance in high-temperature environments.

[0005] The purpose of this utility model can be achieved through the following technical solution: a high temperature resistant and flame retardant power cable for use in robots is proposed, comprising: a plurality of conductor layers and an insulation layer, each conductor layer is covered with the insulation layer, the insulation layer is made of polytetrafluoroethylene material, and the insulation layer and the conductor layer together form an insulated wire core, and the plurality of insulated wire cores are twisted together into a cable core through a filler layer;

[0006] A polyester layer and a low-smoke halogen-free flame-retardant tape are sequentially wrapped around the outside of the cable core to isolate the insulation layer;

[0007] Double shielding layer; covering the low-smoke halogen-free flame-retardant strip, the double shielding layer is used to provide electromagnetic interference protection;

[0008] A flame-retardant buffer layer is wrapped around the double shielding layer. The flame-retardant buffer layer is made of ceramicized silicone rubber material to adapt to the robot's high-frequency bending operation.

[0009] An aramid fiber reinforcement layer is woven outside the flame-retardant buffer layer, and the aramid fiber reinforcement layer is used to enhance the tensile strength of the cable;

[0010] The sheath layer is extruded over the aramid fiber reinforcement layer, and the sheath layer is made of a blend of halogen-free flame-retardant polyether ether ketone and polytetrafluoroethylene.

[0011] In the aforementioned high-temperature resistant and flame-retardant power cable used in robots, the insulation layer is made of polytetrafluoroethylene material with 10%-30% by weight of nano-aluminum hydroxide flame retardant added.

[0012] In the aforementioned high-temperature resistant and flame-retardant power cable used in robots, the conductor layer is made of several strands of silver-plated copper stranded wire with a single filament diameter of 0.12mm.

[0013] In the aforementioned high-temperature resistant and flame-retardant power cable for use in robots, the conductor layer has a stranding diameter ratio of less than or equal to 12, a cross-sectional area of ​​0.5 mm²-50 mm², and is subjected to plasma treatment after stranding to enhance surface adhesion.

[0014] In the aforementioned high-temperature resistant and flame-retardant power cable used in robots, the thickness of the flame-retardant buffer layer is 0.5 mm, and the ceramicized silicone rubber of the flame-retardant buffer layer is flame-retardant in the solid phase, while the halogen-free flame-retardant polyether ether ketone material of the sheath layer is flame-retardant in the gas phase.

[0015] In the aforementioned high-temperature resistant and flame-retardant power cable for use in robots, the cable core is wrapped with the polyester layer and the low-smoke halogen-free flame-retardant tape in an overlapping manner, and the overlap rate of the polyester layer and the low-smoke halogen-free flame-retardant tape is both above 20%.

[0016] In the aforementioned high-temperature resistant and flame-retardant power cable for use in robots, the double shielding layer comprises an aluminum-magnesium alloy foil strip and a copper-nickel alloy wire braided layer. The aluminum-magnesium alloy foil strip is extruded onto the low-smoke halogen-free flame-retardant strip to reflect heat radiation; the copper-nickel alloy wire braided layer is woven outside the aluminum-magnesium alloy foil strip to provide electromagnetic interference protection.

[0017] In the aforementioned high-temperature resistant and flame-retardant power cable used in robots, the braiding density of the copper-plated nickel alloy wire braid layer is above 90%.

[0018] In the aforementioned high-temperature resistant and flame-retardant power cable used in robots, the blending ratio of the halogen-free flame-retardant polyether ether ketone (PEEK) and the polytetrafluoroethylene (PTFE) is 7:3, the thickness is 1.2 mm, and the halogen-free flame-retardant PEEK and PTFE are gradient-distributed through a co-extrusion process.

[0019] In the aforementioned high-temperature resistant and flame-retardant power cable used in robots, the braiding density of the aramid fiber reinforcement layer is above 80%.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] (1) The present invention provides a high temperature resistant and flame retardant power cable for use in robots. Polytetrafluoroethylene is used as the insulation material, which improves the dielectric strength and dielectric loss stability at high temperature. By using a blend of halogen-free flame retardant polyether ether ketone (PEEK) and polytetrafluoroethylene (PTFE) in the sheath layer, combined with ceramicized silicone rubber, a dual flame retardant mechanism of gas phase and solid phase is realized, so that the power cable can still maintain high temperature resistance and high flame retardancy in high temperature environment, thus extending its service life.

[0022] (2) Conductor stranding pitch optimization (pitch ratio ≤ 12) combined with ceramic buffer layer to solve the metal fatigue problem caused by high frequency bending of robot.

[0023] (3) The double-layer shielding structure effectively improves the cable's electromagnetic interference resistance, giving it both high conductivity and flexibility. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of the power cable.

[0025] In the diagram, 1 is the cable core; 10 is the insulated core; 100 is the conductor layer; 101 is the insulation layer; 11 is the filler layer; 2 is the polyester layer; 3 is the low-smoke halogen-free flame-retardant tape; 4 is the double shielding layer; 40 is the aluminum-magnesium alloy foil tape; 41 is the copper-plated nickel alloy wire braided layer; 5 is the flame-retardant buffer layer; 6 is the aramid fiber reinforcement layer; and 7 is the sheath layer. Detailed Implementation

[0026] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0027] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0028] like Figure 1As shown, this utility model discloses a high-temperature resistant and flame-retardant power cable for use in robots, comprising: several conductor layers 100 and an insulation layer 101, each conductor layer 100 being covered by an insulation layer 101, the insulation layer 101 being made of polytetrafluoroethylene (PTFE), and the insulation layer 101 and the conductor layers 100 together forming an insulated core 10, the several insulated cores 10 being twisted together into a cable core 1 by a filler layer 11; a polyester layer 2 and a low-smoke halogen-free flame-retardant tape 3 are sequentially wrapped around the cable core 1 to isolate the insulation layer 10. 1; Double shielding layer 4; Covering the low-smoke halogen-free flame-retardant strip 3, the double shielding layer 4 is used to provide electromagnetic interference protection; Flame-retardant buffer layer 5, covering the double shielding layer 4, the flame-retardant buffer layer 5 is made of ceramicized silicone rubber material to adapt to the high-frequency bending operation of the robot; Aramid fiber reinforcement layer 6, woven on the flame-retardant buffer layer 5, the aramid fiber reinforcement layer 6 is used to enhance the tensile strength of the cable; Sheath layer 7, extruded on the aramid fiber reinforcement layer 6, the sheath layer 7 is made of halogen-free flame-retardant polyetheretherketone and polytetrafluoroethylene blend material.

[0029] In this embodiment, five sets of insulated cores 10 are formed within the cable core 1 (this number is not limited to one case in this embodiment). Each insulated core 10 consists of a conductor layer 100 and an insulation layer 101. In this embodiment, the insulation layer 101 is made of polytetrafluoroethylene (PTFE), which has good electrical insulation, heat resistance, and chemical stability, and can effectively prevent current leakage. As multiple insulated cores 10 are twisted together into the cable core 1 through the filler layer 11, this not only enhances the overall structural strength of the cable but also improves its flexibility, facilitating high-frequency bending operations by robots in complex environments. Preferably, in this embodiment, high-strength flame-retardant fiber is used as filler between the cores, which helps to enhance the tensile strength and torsional performance of the cable while maintaining a circular and flame-retardant structure. In conjunction with the polyester layer 2 and the low-smoke halogen-free flame-retardant tape 3 wrapped around the cable core 1 in sequence, additional physical protection is provided. Furthermore, this embodiment also incorporates a double shielding layer 4 wrapped around a low-smoke halogen-free flame-retardant strip 3 to resist external electromagnetic interference and ensure stable signal transmission. The flame-retardant buffer layer 5 is made of ceramicized silicone rubber, which maintains elasticity at high temperatures, providing the cable with excellent bending resistance and adapting to the dynamic working environment of robots. An aramid fiber reinforcement layer 6 is woven around the outer layer; the high strength and lightweight characteristics of aramid fibers significantly improve the tensile strength of the cable and extend its service life. The sheath layer 7 is extruded from a blend of halogen-free flame-retardant polyetheretherketone and polytetrafluoroethylene, which not only possesses excellent wear resistance, corrosion resistance, and weather resistance, but also effectively inhibits flame spread in the event of a fire, protecting the internal structure from damage and ensuring the reliable operation of the power cable in harsh environments.

[0030] Furthermore, this embodiment employs composite insulation technology. Specifically, in the polytetrafluoroethylene (PTFE) material used in the insulation layer 101, this embodiment also adds 10%-30% by weight of nano-aluminum hydroxide flame retardant to the PTFE material. It is precisely because of the addition of nano-aluminum hydroxide that this composite material not only inherits the excellent electrical properties and heat resistance of PTFE, but also shows significant improvements in flame retardancy and smoke suppression. Therefore, this nanocomposite helps to improve dielectric strength while reducing high-temperature dielectric loss.

[0031] Preferably, in this embodiment, the insulating layer 101 is coated by extrusion to enhance the adhesion between it and the conductor. The performance parameters of the insulating layer 101 are as follows: dielectric strength ≥ 40 kV / mm, volume resistivity ≥ 10¹⁷ Ω.cm, oxygen index (OI) ≥ 38 (ASTM D2863).

[0032] Furthermore, this embodiment selects a 0.12mm diameter monofilament silver-plated copper wire as the base material. The silver plating treatment increases the surface smoothness and oxidation resistance of the copper wire. When multiple silver-plated copper monofilaments are bundled together according to a certain stranding direction and pitch, the stranding process can increase the flexibility of the conductor, making it easier to bend and adapt to the needs of frequent robot movement or bending. At the same time, this stranding structure helps to reduce the impact of electromagnetic interference (EMI) and improve signal transmission quality.

[0033] The conductor layer 100 has a stranding pitch ratio of less than or equal to 12 and a cross-sectional area of ​​0.5 mm²-50 mm². After stranding, the conductor layer 100 is subjected to plasma treatment to enhance surface adhesion.

[0034] More preferably, this embodiment, by controlling the stranding pitch ratio within a small range, can effectively reduce AC resistance and mitigate the effects of skin effect and proximity effect, making it particularly suitable for high-frequency signal transmission applications. A suitable stranding structure improves the conductor's flexibility and tensile strength, making it more adaptable to the frequent bending requirements of dynamic robot operations and extending its service life. Furthermore, plasma treatment significantly enhances the adhesion between the conductor surface and other materials. This improvement is crucial for ensuring the insulation layer 101 and other protective layers are firmly attached to the conductor, improving high-temperature oxidation resistance and conductivity, resisting dynamic fatigue, and further enhancing the overall reliability of the cable. The performance parameters of this structure are as follows: conductivity ≥92% IACS (International Annealed Copper Standard), tensile strength ≥450MPa, temperature rating: -60℃~+300℃ (short-term peak 350℃), bending fatigue life ≥5 million cycles (ASTM D412 test).

[0035] The cable core 1 is wrapped with an overlapping polyester layer 2 and a low-smoke halogen-free flame-retardant strip 3, with the overlap rate of the polyester layer 2 and the low-smoke halogen-free flame-retardant strip 3 both being over 20%.

[0036] like Figure 1 As shown, after the aforementioned insulated cores 10mm diameter and filling layers 11 are twisted into cable core 1, polyester tape (i.e., polyester layer 2) is uniformly wound around the outside of cable core 1 with a certain tension, ensuring an overlap rate of at least 20% between each turn. This step not only provides preliminary mechanical protection but also plays a certain role in isolation. Next, low-smoke halogen-free flame-retardant tape 3 is used again for overlapping wrapping outside the polyester layer 2, while maintaining an overlap rate of at least 20%. This step further enhances the fire resistance of the cable and reduces the generation of toxic fumes in the event of a fire. In other words, by adopting an overlapping wrapping method and ensuring sufficient overlap, the power cable makes the cable core 1 more compact and round, isolating the shielding layer and the insulation layer 101, achieving a better flame-retardant effect and extending the service life of the cable.

[0037] The double shielding layer 4 includes an aluminum-magnesium alloy foil strip 40 and a copper-nickel alloy wire braided layer 41. The aluminum-magnesium alloy foil strip 40 is extruded onto the low-smoke halogen-free flame-retardant strip 3 to reflect heat radiation; the copper-nickel alloy wire braided layer 41 is woven outside the aluminum-magnesium alloy foil strip 40 to provide electromagnetic interference protection.

[0038] like Figure 1 As shown, this embodiment features a double-layer shielding structure outside the low-smoke halogen-free (high) flame-retardant tape. After the cable core 1, polyester layer 2, and low-smoke halogen-free flame-retardant tape 3 are wrapped together, a moderately thick aluminum-magnesium alloy foil strip 40 is evenly wrapped around the surface of the low-smoke halogen-free flame-retardant tape 3 using a specialized extrusion device. This aluminum-magnesium alloy foil has excellent thermal conductivity and heat reflection properties, effectively blocking the influence of heat radiation on the internal structure of the cable in high-temperature or near-heat source environments. Outside the aluminum-magnesium alloy foil strip 40, a second layer of shielding structure is formed by weaving and covering with fine-diameter copper-nickel alloy wire. The copper-nickel alloy wire has excellent conductivity and permeability, effectively absorbing or reflecting external electromagnetic waves to prevent interference with internal signal transmission and ensure the stability of power and control signals. Therefore, this double-layer shielding structure improves electromagnetic interference resistance while also providing conductivity and flexibility.

[0039] Preferably, in this embodiment, the braiding density of the copper-nickel alloy wire braided layer 41 is above 90%. A braiding density of over 90% means that the braided layer has almost no gaps, which can more effectively block the intrusion of external electromagnetic waves and reduce the possibility of internal signals leaking outward. This is especially important for applications requiring highly stable signal transmission. Furthermore, the high-density braiding increases the overall thickness and robustness of the braided layer, enhancing the cable's resistance to external physical damage (such as abrasion and tension), and helping to extend the cable's service life.

[0040] The thickness of the flame-retardant buffer layer 5 is 0.5 mm, and the ceramicized silicone rubber of the flame-retardant buffer layer 5 is flame-retardant in the solid phase, while the halogen-free flame-retardant polyether ether ketone material of the sheath layer 7 is flame-retardant in the gas phase.

[0041] More preferably, such as Figure 1 As shown, in this embodiment, a 0.5mm thick flame-retardant buffer layer 5 is extruded over the copper-nickel alloy wire braided layer 41. This design ensures sufficient mechanical strength while maintaining good flexibility. Simultaneously, the ceramicized silicone rubber transforms into a hard ceramic-like substance at high temperatures, effectively isolating heat and oxygen, preventing further flame spread, and providing an additional safety barrier for the cable. This allows the cable to withstand frequent bending movements by the robot without damage. Furthermore, nano-aluminum hydroxide is added to the halogen-free flame-retardant polyetheretherketone material of the sheath layer 7. This nano-aluminum hydroxide decomposes at high temperatures, releasing water vapor and absorbing a large amount of heat. This helps reduce the temperature of the combustion zone, inhibiting flame spread, and thus greatly improving the flame-retardant performance of the cable. The structural performance parameters are as follows: forming a ceramic hard shell at high temperatures (no dripping at 1000℃ / 30min), limiting oxygen index (LOI) ≥45.

[0042] More preferably, in this embodiment, the braiding density of the aramid fiber reinforcing layer 6 is 80% or higher. High-density braiding helps to improve the tensile strength of the cable, with a tensile strength ≥500N / mm², enabling the cable to maintain good performance even under frequent robot movement or bending.

[0043] The blending ratio of halogen-free flame-retardant polyetheretherketone (PEEK) and polytetrafluoroethylene (PTFE) is 7:3, with a thickness of 1.2 mm. The gradient distribution of halogen-free flame-retardant PEEK and PTFE is achieved through a co-extrusion process.

[0044] This embodiment also includes an outer sheath layer 7 extruded over the aramid fiber reinforcement layer 6. To achieve a gradient distribution of halogen-free flame-retardant polyether ether ketone (PEEK) and polytetrafluoroethylene (PTFE) in the sheath layer 7, a special co-extrusion process is employed. This process allows the two materials to gradually change in different proportions during extrusion. In actual operation, it is necessary to precisely control the temperature, pressure, and feed rate of the two materials in the extruder to ensure that the final product achieves the expected gradient distribution effect. That is, PEEK provides better mechanical protection and high-temperature resistance for the cable, while the outer surface (PTFE) improves the cable's abrasion resistance, corrosion resistance, and electrical insulation performance. The structural performance parameters are as follows: tensile strength ≥120 MPa, flame retardant rating: UL94 V-0 (vertical burning), oil resistance (strength retention rate ≥90% after immersion at 70℃ / 168h), temperature resistance above 300℃, low coefficient of friction, suitable for repeated bending of robot joints.

[0045] It should be noted that in this invention, the use of terms such as "first," "second," and "a" is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified. The terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two elements or the interaction between two elements, unless otherwise explicitly specified. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0046] Furthermore, the technical solutions of the various embodiments of the present invention can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by the present invention.

[0047] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A high-temperature resistant and flame-retardant power cable for use in robots, characterized in that, include: The cable consists of several conductor layers and an insulating layer, with each conductor layer covered by an insulating layer. The insulating layer is made of polytetrafluoroethylene (PTFE) and together with the conductor layers, forms an insulated core. The insulated cores are stranded together with a filler layer to form a cable core. A polyester layer and a low-smoke halogen-free flame-retardant tape are sequentially wrapped around the outside of the cable core to isolate the insulation layer; Double shielding layer; covering the low-smoke halogen-free flame-retardant strip, the double shielding layer is used to provide electromagnetic interference protection; A flame-retardant buffer layer is wrapped around the double shielding layer. The flame-retardant buffer layer is made of ceramicized silicone rubber material to adapt to the robot's high-frequency bending operation. An aramid fiber reinforcement layer is woven outside the flame-retardant buffer layer, and the aramid fiber reinforcement layer is used to enhance the tensile strength of the cable; The sheath layer is extruded over the aramid fiber reinforcement layer, and the sheath layer is made of a blend of halogen-free flame-retardant polyether ether ketone and polytetrafluoroethylene.

2. The high-temperature resistant and flame-retardant power cable for use in robots according to claim 1, characterized in that, The insulation layer is made of polytetrafluoroethylene material with 10%-30% by weight of nano-aluminum hydroxide flame retardant added.

3. The high-temperature resistant and flame-retardant power cable for use in robots according to claim 1, characterized in that, The conductor layer is made of several strands of silver-plated copper wire with a single filament diameter of 0.12 mm twisted together.

4. A high-temperature resistant and flame-retardant power cable for use in robots according to claim 1 or 3, characterized in that, The conductor layer has a stranding pitch ratio of less than or equal to 12 and a cross-sectional area of ​​0.5 mm²-50 mm². After stranding, the conductor layer is subjected to plasma treatment to enhance surface adhesion.

5. A high-temperature resistant and flame-retardant power cable for use in robots according to claim 1, characterized in that, The thickness of the flame-retardant buffer layer is 0.5 mm, and the ceramicized silicone rubber of the flame-retardant buffer layer is flame-retardant in the solid phase, while the halogen-free flame-retardant polyether ether ketone material of the sheath layer is flame-retardant in the gas phase.

6. The high-temperature resistant and flame-retardant power cable for use in robots according to claim 1, characterized in that, The cable core is wrapped with the polyester layer and the low-smoke halogen-free flame-retardant tape in an overlapping manner, and the overlap rate of the polyester layer and the low-smoke halogen-free flame-retardant tape is both more than 20%.

7. A high-temperature resistant and flame-retardant power cable for use in robots according to claim 6, characterized in that, The dual shielding layer comprises an aluminum-magnesium alloy foil strip and a copper-nickel alloy wire braided layer. The aluminum-magnesium alloy foil strip is extruded onto the low-smoke halogen-free flame-retardant strip to reflect heat radiation. The copper-nickel alloy wire braided layer is woven outside the aluminum-magnesium alloy foil strip to provide electromagnetic interference protection.

8. A high-temperature resistant and flame-retardant power cable for use in robots according to claim 7, characterized in that, The braiding density of the copper-nickel alloy wire braided layer is above 90%.

9. A high-temperature resistant and flame-retardant power cable for use in robots according to claim 1, characterized in that, The blending ratio of the halogen-free flame-retardant polyether ether ketone (PEEK) and the polytetrafluoroethylene (PTFE) is 7:3, the thickness is 1.2 mm, and the halogen-free flame-retardant PEEK and PTFE are gradient-distributed through a co-extrusion process.

10. A high-temperature resistant and flame-retardant power cable for use in robots according to claim 1, characterized in that, The weaving density of the aramid fiber reinforcing layer is above 80%.

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