A corrosion-resistant and tensile-resistant integrated protective control cable

Abstract

This utility model relates to a corrosion-resistant and tensile-resistant comprehensive protective control cable, belonging to the field of control cable technology. The technical solution is as follows: A tin-plated copper conductor is extruded and stranded with 105℃ irradiated cross-linked polyethylene to form an insulated core. Multiple insulated cores are wrapped with polyester film tape. The polyester film tape is then surrounded by a tin-plated copper wire braided shield. This tin-plated copper wire braided shield is further surrounded by the polyester film tape. A PVC inner sheath is then extruded over the polyester film tape. A lead sheath is then extruded over the PVC inner sheath. A second PVC inner sheath is then extruded over the lead sheath. The second PVC inner sheath is then surrounded by a flat galvanized steel wire armor. This flat galvanized steel wire armor is then surrounded by a non-woven fabric. Finally, the non-woven fabric is extruded over a PVC outer sheath. This utility model, through its double-layer protective structure design of a lead sheath and flat galvanized steel wire armor, improves the cable's comprehensive protection capability and service life in complex chemical environments, ensuring the stable operation of electrical systems during chemical production processes.

Description

Technical Field

[0001] This utility model relates to a corrosion-resistant and tensile-strength integrated protective control cable, belonging to the field of control cable technology. It is particularly suitable for chemical application scenarios with harsh corrosive environments and high requirements for cable waterproofing and mechanical performance, such as chemical production plants, sewage treatment systems, and storage tank areas. Background Technology

[0002] In the chemical industry, existing technologies use PVC (polyvinyl chloride) and cross-linked polyethylene (XLPE) as insulation materials for control cables. The long-term allowable operating temperatures for these cables are 70℃ and 90℃, respectively. Sheath materials are mostly common materials such as PVC, polyethylene, and halogen-free polyolefins. For example, Chinese patent application CN 202021369743.3, entitled "A Ternary EPDM Insulated Chlorosulfonated Polyethylene Sheathed Wind Power Control Cable," faces numerous challenges in practical applications. Chemical production involves complex corrosive media such as acids, alkalis, salts, and organic solvents, which ordinary plastics and metals cannot withstand, leading to cable damage and disrupting normal chemical production. High temperature and humidity in chemical workshops, long-term immersion in sewage pools, and salt spray corrosion in open-air storage areas accelerate the aging of cable insulation, reduce service life, and increase cable replacement costs and maintenance difficulty.

[0003] Existing cable tensile armor often uses a round steel wire design, which has good tensile strength but weak resistance to lateral pressure. In actual use, cables are subjected not only to tensile force but also to lateral pressure. At this time, the disadvantages of round steel wire armor become apparent: because the contact area between the round steel wire and the cable inner lining is small and the diameter is thin, when subjected to lateral pressure, the pressure of the stressed steel wire on the cable body increases, which can cause indentations in the inner lining and, in severe cases, damage the insulated core, affecting signal transmission. Utility Model Content

[0004] The purpose of this utility model is to provide a corrosion-resistant and tensile-resistant comprehensive protection control cable. Through the double-layer protection structure design of lead sheath and flat galvanized steel wire armor, the cable's comprehensive protection capability and service life in complex chemical environments are improved, ensuring the stable operation of electrical systems in chemical production processes, and effectively solving the technical problems of insufficient corrosion resistance, waterproofing, temperature resistance, and mechanical performance protection of traditional control cables.

[0005] The technical solution of this utility model is:

[0006] A corrosion-resistant and tensile-resistant integrated protective control cable comprises a tinned copper conductor, 105℃ irradiated cross-linked polyethylene, a polyester film wrapping tape, a tinned copper wire braided shield, a polyester film wrapping tape, a PVC inner sheath, a lead sheath, a PVC inner sheath, a flat galvanized steel wire armor, non-woven fabric, and a PVC outer sheath. The tinned copper conductor is extruded with 105℃ irradiated cross-linked polyethylene and then stranded into an insulated core. Multiple insulated cores are wrapped with polyester film wrapping tape. The polyester film wrapping tape is then wrapped with a tinned copper wire braided shield. The tinned copper wire braided shield is then wrapped with polyester film wrapping tape. The polyester film wrapping tape is then extruded with a PVC inner sheath, which is then extruded with a lead sheath. The lead sheath is then extruded with a PVC inner sheath, which is then wrapped with a flat galvanized steel wire armor. The steel wire armor is then wrapped with non-woven fabric, and the non-woven fabric is then extruded with a PVC outer sheath.

[0007] Furthermore, the tin-plated copper wire braided shield is made of tin-plated copper wire.

[0008] Furthermore, the PVC inner sheath is a first layer of inner sheath, which is wrapped around the tin-plated copper wire braided shield by an extrusion process.

[0009] Furthermore, the lead sheath is wrapped around the outer layer of the PVC inner sheath using an extrusion process.

[0010] Furthermore, the second PVC inner sheath is a second inner sheath, which is again made of PVC material extruded over the lead sheath.

[0011] Furthermore, the flat galvanized steel wire armor uses flat galvanized steel wire material processed by a steel wire preforming device and a cable pre-stretching device, which is spirally wound onto the outer side of the PVC inner sheath by an armoring machine according to a set spiral pitch and winding angle.

[0012] Furthermore, the PVC outer sheath is made of flame-retardant polyvinyl chloride material through extrusion.

[0013] The beneficial effects of this utility model are as follows: It adopts a double-layer protective structure consisting of a lead sheath and flat galvanized steel wire armor. The lead sheath provides excellent corrosion resistance and sealing, effectively resisting various corrosive media in chemical environments. The sealing of the lead sheath prevents liquid from seeping into the cable, avoiding insulation aging or short-circuit risks. Simultaneously, the sealing of the lead sheath prevents flammable gases from seeping into the cable, reducing the risk of explosion caused by electrical sparks. The flat galvanized steel wire armor overcomes the shortcomings of round steel wire in resisting lateral pressure, while also possessing excellent tensile strength. The high-performance steel wire armor layer provides strong mechanical protection, withstanding tensile forces from chemical equipment and material compression, protecting the integrity of the cable's internal structure. This double-layer protective structure greatly improves the cable's comprehensive protection capabilities in complex chemical environments. Furthermore, it uses irradiated cross-linked polyethylene material at 105℃, increasing the temperature resistance of traditional cross-linked polyethylene (XLPE) from 90℃ to 105℃. This results in excellent electrical insulation, heat resistance, and chemical stability, maintaining stable performance even in the high-temperature environments of chemical production. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of an embodiment of the present utility model;

[0015] In the diagram: 1. Tinned copper conductor; 2. Cross-linked polyethylene irradiated at 105℃; 3. Polyester film wrapping tape 1; 4. Tinned copper wire braided shield; 5. Polyester film wrapping tape 2; 6. PVC inner sheath 1; 7. Lead sheath; 8. PVC inner sheath 2; 9. Flat galvanized steel wire armor; 10. Non-woven fabric; 11. PVC outer sheath. Detailed Implementation

[0016] The present invention will be further described below with reference to the accompanying drawings and examples.

[0017] See attached document Figure 1 A corrosion-resistant and tensile-resistant integrated protective control cable comprises a tinned copper conductor 1, 105℃ irradiated cross-linked polyethylene 2, polyester film wrapping tape 3, tinned copper wire braided shielding 4, polyester film wrapping tape 5, PVC inner sheath 6, lead sheath 7, PVC inner sheath 8, flat galvanized steel wire armor 9, non-woven fabric 10, and PVC outer sheath 11. The tinned copper conductor 1 is extruded with 105℃ irradiated cross-linked polyethylene 2 and then stranded into insulated cores. Multiple insulated cores are further... 3. Polyester film wrapping tape; 4. Polyester film wrapping tape with tinned copper wire braided shield; 5. Tinned copper wire braided shield with polyester film wrapping tape; 6. Polyester film wrapping tape with PVC inner sheath (first type); 7. PVC inner sheath (first type) with lead sheath (extruded); 8. Lead sheath (7) with PVC inner sheath (second type); 9. PVC inner sheath with flat galvanized steel wire armor (second type); 10. Flat galvanized steel wire armor (9) with non-woven fabric wrapping; 11. Non-woven fabric with PVC outer sheath (extruded).

[0018] In this embodiment: the tin-plated copper conductor 1 is made of high-purity oxygen-free copper rod, manufactured through wire drawing, tin plating, and stranding processes. It possesses excellent electrical conductivity. The tin layer, as a dense metallic plating layer, adheres tightly to the surface of the copper conductor, forming an insulating protective layer that prevents direct contact between the copper and external corrosive media (such as oxygen, moisture, salt spray, sulfides, acidic and alkaline gases, etc.), thereby delaying copper oxidation and corrosion, ensuring stable current transmission, and meeting the accuracy requirements of chemical equipment for control signals and power transmission.

[0019] The 105℃ irradiated cross-linked polyethylene 2 uses irradiated cross-linked polyethylene material, increasing the temperature resistance of traditional cross-linked polyethylene (XLPE) from 90℃ to 105℃. It is tightly coated onto the copper conductor through an extrusion process. The 105℃ irradiated cross-linked polyethylene material possesses excellent electrical insulation properties, heat resistance (long-term operating temperature up to 105℃), and chemical stability, maintaining stable performance even in the high-temperature environments of chemical production.

[0020] The tinned copper wire braided shield 4 is made of tinned copper wire. It can effectively shield electromagnetic interference generated by complex electrical equipment in chemical environments, ensure the accuracy of cable signal transmission, and at the same time provide mechanical protection for the internal insulation layer.

[0021] The PVC inner sheath 6 is the first inner sheath, which is extruded over the tinned copper wire braided shield. It has a certain degree of flexibility and mechanical strength, further protecting the internal structure and preventing the lead sheath from damaging the insulated core. At the same time, it provides a flat surface for the lead sheath, ensuring a tight fit between the lead sheath and the internal structure.

[0022] The lead sheath 7 is extruded over the PVC inner sheath 6. Lead has good flexibility, corrosion resistance, and sealing properties, and can resist corrosion from common acid, alkali, salt solutions, and organic solvents in chemical environments. It effectively prevents moisture from penetrating the cable and protects the internal insulation layer and conductor of the cable from chemical corrosion.

[0023] The PVC inner sheath 8 is the second inner sheath, which is extruded with PVC material again on the outside of the lead sheath 7 to provide secondary protection for the lead sheath 7 and prevent damage to the lead sheath 7 during subsequent processing, installation and use. At the same time, it provides a stable support structure for the steel wire armor layer and prevents the steel wire armor from damaging the internal structure of the cable.

[0024] The flat galvanized steel wire armor 9 uses flat galvanized steel wire material, which is processed by a steel wire pre-forming device and a cable pre-stretching device to solve the problems of stress rebound and cable stress rotation after high-strength steel wire armoring. It is spirally wound onto the outside of the PVC inner sheath 8 by an armoring machine according to a set spiral pitch and winding angle. The galvanized steel wire armor has excellent tensile and compressive strength, and can withstand mechanical forces such as vibration from chemical equipment, material accumulation and compression, and external impacts, protecting the integrity of the cable's internal structure and ensuring the cable's normal operation in complex mechanical environments.

[0025] The PVC outer sheath 11 is extruded from flame-retardant polyvinyl chloride material, which has good flame retardancy, weather resistance, wear resistance and anti-aging properties. It can resist natural factors such as ultraviolet rays and temperature changes in the chemical environment, while preventing external sharp objects from damaging the internal structure and further extending the service life of the cable.

Claims

1. A corrosion-resistant and tensile comprehensive protection control cable, characterized in that: It includes a tinned copper conductor (1), 105°C irradiated cross-linked polyethylene (2), polyester film tape one (3), tinned copper wire braided shield (4), polyester film tape two (5), PVC inner sheath one (6), lead sheath (7), PVC inner sheath two (8), flat galvanized steel wire armor (9), non-woven fabric (10) and PVC outer sheath (11). After extruding 105°C irradiated cross-linked polyethylene (2) outside the tinned copper conductor (1), it is stranded into an insulated wire core. Polyester film tape one (3) is wrapped around multiple insulated wire cores. Tinned copper wire braided shield (4) is braided outside the polyester film tape one (3). Polyester film tape two (5) is wrapped outside the tinned copper wire braided shield (4). PVC inner sheath one (6) is extruded outside the polyester film tape two (5). Lead sheath (7) is extruded outside the PVC inner sheath one (6). PVC inner sheath two (8) is extruded outside the lead sheath (7). Flat galvanized steel wire armor (9) is wrapped around the PVC inner sheath two (8). Non-woven fabric (10) is wrapped outside the flat galvanized steel wire armor (9). PVC outer sheath (11) is extruded outside the non-woven fabric (10).

2. The corrosion-resistant and tensile comprehensive protection control cable according to claim 1, characterized in that: The flat galvanized steel wire armor (9) uses flat galvanized steel wire material processed by a steel wire pre-forming device and a cable pre-stretching device, and is spirally wound outside the PVC inner sheath two (8) by an armor machine according to a set spiral pitch and winding angle.

3. The corrosion-resistant and tensile comprehensive protection control cable according to claim 1 or 2, characterized in that: The PVC outer sheath (11) is extruded from a flame-retardant polyvinyl chloride material.

Images