A wear-resistant graphene cable

Abstract

This utility model belongs to the field of cables, specifically a wear-resistant graphene cable. Addressing the problem that existing cables have large contact areas with conduits, increasing cable wear and making conduit installation more difficult, the following solution is proposed: It includes multiple copper conductor bodies, each with an outer wall wrapped with a flame-retardant layer, all integrally formed within a filler layer. In this utility model, the rigid support of the graphene metal core copper conductor body and the aramid fiber braided layer, combined with the flexible buffering of rubber-foam cotton-epoxy resin, forms a dynamic stress balance mechanism. This ensures the cable's mechanical reliability while reducing environmental wear risks through surface smoothing. This structure and material also enable breakthroughs in wear resistance, impact resistance, conductivity stability, and environmental adaptability, allowing for wide application in harsh environments such as high wear and strong vibration.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, and in particular to a wear-resistant graphene cable. Background Technology

[0002] Graphene cables are a new type of cable made using graphene, a revolutionary nanomaterial. The core of this technology lies in integrating the excellent physical properties of graphene into the traditional cable structure, thereby breaking through the performance bottleneck of traditional cables.

[0003] During the underground laying of cables through conduits, the cables will rub against the inside of the pre-buried conduits. Although the surface of the cable is relatively smooth to reduce the friction between it and the pre-buried conduit, the large contact area between the cable and the conduit not only increases the wear on the cable but also increases the difficulty of laying the cable through the conduit. Utility Model Content

[0004] The purpose of this invention is to address the shortcomings of existing technologies, such as the large contact area between cables and pipes, which not only increases cable wear but also makes pipe installation more difficult. Therefore, this invention proposes a wear-resistant graphene cable.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A wear-resistant graphene cable, comprising:

[0007] Multiple copper conductor bodies, the outer walls of the multiple copper conductor bodies are wrapped with a flame-retardant layer, the flame-retardant layer is ceramicized silicone rubber, the multiple flame-retardant layers are integrally formed in a filler layer, the outer wall of the filler layer is sequentially provided with a shielding layer, a first adhesive layer, a buffer layer, a second adhesive layer, a braided layer, an insulating layer and an anti-wear layer, the shielding layer is a copper-plastic composite tape;

[0008] The outer wall of the wear-resistant layer is distributed with multiple wear-resistant balls, and adjacent rows of wear-resistant balls are staggered. The outer walls of both the wear-resistant layer and the wear-resistant balls are coated with a smooth coating material made of polyvinyl chloride to reduce friction at contact points and reduce wear on cables and pipes.

[0009] In one possible design, the insulating layer is made of rubber, and the braided layer is made of aramid fiber braid.

[0010] In one possible design, the inner and outer walls of the buffer layer are provided with multiple support strips, and both the buffer layer and the support strips are composite layers of rubber and foam cotton.

[0011] In one possible design, both the first adhesive layer and the second adhesive layer are flexible epoxy resin adhesives. The outer wall of the first adhesive layer and the inner wall of the second adhesive layer are provided with multiple mating grooves, and the size of the support strip matches the size of the mating grooves, so as to achieve mechanical interlocking and suppress interlayer slippage.

[0012] In one possible design, the copper conductor body is made of graphene metal core.

[0013] In one possible design, the coefficient of friction of the smooth coating is ≤0.15.

[0014] In one possible design, the anti-wear balls have a protrusion height of 0.5 mm to 2 mm, are distributed in 4-8 rows circumferentially, and have an axial spacing of 3 mm to 7 mm.

[0015] In one possible design, the support bar is embedded in a mating groove and fixed by adhesive with flexible epoxy resin to form a multi-stage energy dissipation mechanism.

[0016] In one possible design, the braided layer provides cut resistance, and the insulating layer absorbs impact energy through deformation.

[0017] In this application, multiple copper conductors are respectively wrapped in flame-retardant layers, which are wrapped in filler layers. The outer wall of the filler layer is wrapped with a shielding layer, and the outer wall of the shielding layer is wrapped with a first adhesive layer. A buffer layer is provided between the first adhesive layer and the second adhesive layer. The inner and outer walls of the buffer layer are integrally formed with multiple support strips, and the multiple support strips on the inner and outer walls are respectively fitted and fixed with multiple mating grooves on the outer wall of the first adhesive layer and the inner wall of the second adhesive layer. The outer wall of the second adhesive layer is wrapped with an insulating layer. The wear-resistant balls are integrally formed with the wear-resistant layer. Multiple wear-resistant balls are distributed on the outer wall of the wear-resistant layer. The wear-resistant balls in two adjacent rows are staggered, and the outer walls of the wear-resistant layer and the wear-resistant balls are coated with a smooth coating.

[0018] Beneficial effects: In this utility model, the wear-resistant graphene cable has an outermost wear-resistant layer with a staggered arrangement of multiple sets of wear-resistant balls, combined with a smooth coating, which effectively disperses external friction and reduces the contact area of ​​wear points; the braided layer and the insulation layer form a rigid-flexible protective barrier, the former providing high-strength cut resistance, and the latter absorbing impact energy through deformation; the rubber-foam cotton combination structure of the middle second adhesive layer further buffers vibration, and with the elastic bonding of the flexible epoxy resin first adhesive layer and the second adhesive layer, multi-level energy dissipation is achieved, so that the cable can still maintain structural integrity under complex working conditions;

[0019] In this utility model, the wear-resistant graphene cable features a design where the dimensions of the support bar and the mating groove match to create a mechanical interlocking of the inner structure. Combined with the bonding of flexible epoxy resin, this effectively inhibits interlayer slippage and improves tensile strength. The graphene metal core copper conductor not only gives the cable excellent conductivity, but its high modulus characteristics also enhance its overall resistance to deformation. Furthermore, the composite application of the smooth outer coating and the internal flexible material gives the cable both a low coefficient of friction and high wear resistance, significantly extending its service life.

[0020] In this invention, the rigid support of the graphene metal core copper conductor and the aramid fiber braided layer, combined with the flexible buffer of rubber-foam cotton-epoxy resin, forms a dynamic stress balance mechanism, which not only ensures the mechanical reliability of the cable, but also reduces the risk of environmental wear through surface smoothing treatment. This structure and material also enable the cable to achieve breakthroughs in wear resistance, impact resistance, conductivity stability and environmental adaptability, and can be widely used in harsh scenarios such as high wear and strong vibration. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of a wear-resistant graphene cable proposed in this utility model;

[0022] Figure 2 This is a cross-sectional structural diagram of a wear-resistant graphene cable insulation layer proposed in this utility model;

[0023] Figure 3 This is an exploded structural diagram of the wear-resistant graphene cable buffer layer, the first adhesive layer, and the second adhesive layer proposed in this utility model.

[0024] Figure 4 This is a cross-sectional view of the graphene cable filling layer proposed in this utility model.

[0025] In the diagram: 1. Abrasion-resistant layer; 2. Insulation layer; 3. Copper conductor body; 4. Buffer layer; 5. Abrasion-resistant ball; 6. Braided layer; 7. Support strip; 8. First adhesive layer; 9. Mating groove; 10. Second adhesive layer; 11. Flame retardant layer; 12. Shielding layer; 13. Filler layer. Detailed Implementation

[0026] 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.

[0027] In one embodiment: Refer to Figure 1 and Figure 4A wear-resistant graphene cable uses graphene metal composite wire as the copper conductor body 3. The wire core with a diameter of 0.2mm is formed by continuous wire drawing process. A single cable contains 36 such wire cores. The surface of each copper conductor body 3 is covered with a flame retardant layer 11. Ceramicized silicone rubber is wrapped around the wire core by extrusion coating. The coating thickness is 0.15mm. The cable is then vulcanized at 200℃.

[0028] Reference Figure 1 and Figure 4 The 36 copper conductors 3, each wrapped with a flame-retardant layer 11, are arranged in a regular hexagonal pattern, with an asbestos filling layer 13 at the center. The stranding and filling are completed simultaneously on a vertical cabling machine. The filling layer 13 completely covers all flame-retardant layers 11, with an outer diameter controlled at 8.5 mm. A copper-plastic composite tape is longitudinally wrapped around the outer surface of the filling layer 13 to form a shielding layer 12, with ultrasonic welding used at the overlaps.

[0029] Reference Figure 1 , Figure 3 and Figure 4 A first adhesive layer 8 is applied to the outside of the shielding layer 12. Flexible epoxy resin (Shore hardness A50) is evenly coated to a thickness of 0.1 mm. Before curing, 24 circumferentially distributed mating grooves 9 are molded on its surface, with a depth of 0.8 mm and a width of 1.2 mm. A pre-fabricated buffer layer 4 is formed by hot-pressing nitrile rubber and closed-cell foam cotton, with a total thickness of 1.5 mm. 24 support strips 7 are molded on the inner surface, with a height of 0.8 mm and a width of 1.2 mm, matching the dimensions of the mating grooves 9. After the support strips 7 are precisely embedded into the mating grooves 9, they are hot-pressed and cured at 120°C for 30 minutes to achieve bonding.

[0030] Reference Figure 1 , Figure 3 and Figure 4 The outer surface of the buffer layer 4 is coated with a second adhesive layer 10 (of the same material as the first adhesive layer 8), and 24 mating grooves 9 are molded. A braided layer 6 is wrapped around the second adhesive layer 10: 1680D aramid fiber is braided into a tubular sheath at a 45° angle by a 96-spindle braiding machine, with a coverage rate of ≥90%. An insulating layer 2 is extruded around the braided layer 6: EPDM rubber is wrapped by a 90mm extruder with a thickness of 1.2mm and a vulcanization temperature of 170℃.

[0031] In another embodiment: Reference Figure 2 A wear-resistant graphene cable comprises an anti-wear layer 1 molded onto the surface of an insulation layer 2, using polyurethane elastomer continuously formed through a roller mold with a hemispherical cavity. Anti-wear balls 5 are arranged in six circumferential rows, with an axial spacing of 5 mm between each row and adjacent rows staggered by 30°. The balls have a diameter of 3 mm and a protrusion height of 1.2 mm. A smooth polytetrafluoroethylene coating with a thickness of 15 μm is sprayed onto the surfaces of the anti-wear layer 1 and the anti-wear balls 5, and cured at 150°C to form a surface with a friction coefficient ≤0.15.

[0032] The accompanying drawings in this application are for illustrative purposes only. The dimensions and shapes of the components shown are not actual limitations but are merely schematic representations. In actual implementation, the components can be reasonably configured and adjusted according to specific needs and actual conditions.

[0033] 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. An abrasion resistant graphene cable, characterized by, include: Multiple copper conductor bodies (3) are wrapped with flame-retardant layers (11) on their outer walls. The flame-retardant layers (11) are ceramicized silicone rubber. Multiple flame-retardant layers (11) are integrally formed in a filling layer (13). The outer wall of the filling layer (13) is sequentially provided with a shielding layer (12), a first adhesive layer (8), a buffer layer (4), a second adhesive layer (10), a braided layer (6), an insulating layer (2), and an anti-wear layer (1). The shielding layer (12) is a copper-plastic composite tape. The outer wall of the wear-resistant layer (1) is distributed with multiple wear-resistant balls (5), and the adjacent rows of wear-resistant balls (5) are staggered. The outer walls of the wear-resistant layer (1) and the wear-resistant balls (5) are coated with a smooth coating material. The smooth coating material is made of polyvinyl chloride to reduce friction at the contact points and reduce wear on cables and pipes.

2. The attrition resistant graphene cable of claim 1, wherein, The insulating layer (2) is made of rubber, and the braided layer (6) is made of aramid fiber braid.

3. The attrition resistant graphene cable of claim 1, wherein, The inner and outer walls of the buffer layer (4) are provided with multiple support strips (7), and the buffer layer (4) and the support strips (7) are both composite layers of rubber and foam cotton.

4. The attrition resistant graphene cable of claim 3, wherein, Both the first adhesive layer (8) and the second adhesive layer (10) are flexible epoxy resin adhesives. The outer wall of the first adhesive layer (8) and the inner wall of the second adhesive layer (10) are provided with multiple mating grooves (9), and the size of the support strip (7) matches the size of the mating groove (9) to achieve mechanical interlocking and suppress interlayer slippage.

5. The attrition resistant graphene cable of claim 1, wherein, The copper conductor body (3) is made of graphene metal core.

6. The attrition resistant graphene cable of any one of claims 1-3, wherein, The coefficient of friction of the smooth coating is ≤0.

15.

7. The attrition resistant graphene cable of claim 1, wherein, The anti-wear ball (5) has a protrusion height of 0.5 mm to 2 mm, is distributed in 4-8 rows in the circumferential direction, and has an axial spacing of 3 mm to 7 mm.

8. The attrition resistant graphene cable of claim 4, wherein, The support bar (7) is embedded in the mating groove (9) and fixed by adhesive bonding with flexible epoxy resin to form a multi-level energy dissipation mechanism.

9. The attrition resistant graphene cable of claim 1, wherein, The braided layer (6) provides cut resistance, and the insulating layer (2) absorbs impact energy through deformation.

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