A high temperature resistant corrosion resistant PVC power cord of a multi-layer composite structure

Abstract

The utility model relates to the technical field of electric wire and cable, concretely to a multilayer composite structure's high temperature resistance corrosion resistance PVC power line, including conductor core, high temperature resistance PVC insulation inner layer, fluorine material function reinforcing layer, buffer isolation layer and modified PVC corrosion resistant sheath layer, the conductor core adopts the stranding of multiple strands of tinned copper wire, and the interface is combined to enhance by coating coupling agent, and the fluorine material layer significantly improves the chemical corrosion resistance and heat resistance, the buffer isolation layer is the glass fiber cloth strip of dip -coating silicone rubber, and has the high temperature resistance, heat insulation and reinforcing effect, and the interlayer is equipped with hot melt adhesive bonding layer, ensures that the structure is compact and does not delaminate, the function reinforcing layer and buffer layer can be equipped with copper band or aluminium plastic shielding layer, provides electromagnetic protection, and the power line has high temperature resistance, corrosion resistance, insulation stability, high mechanical strength, long service life and the advantages such as, is suitable for high temperature, humid and corrosive industrial environment.

Description

Technical Field

[0001] This utility model relates to the field of wire and cable technology, specifically to a high-temperature and corrosion-resistant PVC power cord with a multi-layer composite structure. Background Technology

[0002] Conventional PVC insulated cables typically only provide basic electrical insulation and mechanical protection. Their temperature resistance generally does not exceed 70℃, and they are prone to softening and deformation in high-temperature environments, leading to a decrease in insulation performance and posing safety hazards. Furthermore, ordinary PVC sheaths have weak resistance to corrosive media such as acids, alkalis, salt spray, and oils. Long-term exposure can cause swelling, embrittlement, or peeling, shortening their service life.

[0003] While existing improved cables attempt to use cross-linked polyethylene or fluoroplastics as insulation or sheathing materials to enhance temperature and corrosion resistance, they suffer from high costs, complex processing, poor flexibility, and incompatible compatibility with PVC systems. Some multi-layered cables lack effective interlayer bonding designs, making them prone to delamination and shell separation, affecting overall performance stability. Furthermore, traditional structures lack buffer layers, making them susceptible to internal damage under bending or vibration conditions.

[0004] Although fiberglass has excellent high-temperature resistance and insulation properties, it is prone to moisture absorption, has uneven mechanical strength, and poor adhesion to the plastic sheath when used directly as an outer layer material. Furthermore, most power cords lack an electromagnetic shielding layer, making them ill-suited for complex industrial environments with high electromagnetic interference. Utility Model Content

[0005] (a) Technical problems to be solved

[0006] To address the shortcomings of existing technologies, this utility model provides a high-temperature and corrosion-resistant PVC power cord with a multi-layer composite structure.

[0007] (II) Technical Solution

[0008] To achieve the above objectives, this utility model provides the following technical solution: A multi-layer composite high-temperature and corrosion-resistant PVC power cord of this utility model, comprising, from the inside out:

[0009] Conductor core;

[0010] The inner insulating layer is made of high-temperature resistant PVC composite material and is wrapped around the outside of the conductor core.

[0011] The functional enhancement layer is made of a fluorine material thin film layer, which is wrapped around the outside of the functional enhancement layer;

[0012] A buffer isolation layer, wrapped around the outside of the functional enhancement layer, is made of glass fiber.

[0013] The corrosion-resistant sheath layer is made of modified PVC composite material and is wrapped around the outside of the buffer isolation layer.

[0014] Preferably, the thickness ratio of the insulating inner layer to the corrosion-resistant sheath layer is 1:1.5-2.5.

[0015] More preferably, the conductor core comprises multiple strands of tin-plated copper wire, which are twisted together, and the outer side of the conductor core is coated with a coupling agent coating.

[0016] Preferably, the buffer layer is a strip-shaped structure, and the buffer layer is coated with silicone rubber.

[0017] Preferably, an adhesive layer is provided between the insulating inner layer and the functional enhancement layer, and the adhesive layer is made of hot melt adhesive.

[0018] In a further preferred embodiment, a shielding layer is provided between the functional enhancement layer and the buffer isolation layer, wherein the shielding layer is a copper strip or an aluminum-plastic strip.

[0019] (III) Beneficial Effects

[0020] Compared with the prior art, this utility model provides a high-temperature and corrosion-resistant PVC power cord with a multi-layer composite structure, which has the following advantages:

[0021] By setting up a conductor core, a high-temperature resistant PVC insulation inner layer, a fluorine material functional enhancement layer, a glass fiber buffer isolation layer, and a modified PVC anti-corrosion sheath layer from the inside out, multi-level synergistic protection is achieved.

[0022] The inner insulation layer uses high-temperature resistant PVC material to ensure stable insulation of the conductor in high-temperature environments. The fluorine film layer possesses excellent chemical corrosion resistance and low dielectric properties, significantly improving the cable's weather resistance and electrical performance. The buffer insulation layer uses a glass fiber cloth strip structure impregnated with silicone rubber, providing good thermal insulation and high-temperature resistance while enhancing interlayer buffering and mechanical strength. The corrosion-resistant sheath layer uses modified PVC material to further resist corrosion from acids, alkalis, salts, and other corrosive media.

[0023] The insulation layer to sheath layer thickness ratio is optimized to 1:1.5–2.5, balancing electrical safety and mechanical protection. The conductor core uses multi-strand tin-plated copper wire twisted together and coated with a coupling agent to improve conductivity, oxidation resistance, and adhesion to the insulation layer. A hot melt adhesive layer and a metal shielding layer are added to enhance interlayer adhesion and provide electromagnetic shielding.

[0024] With a reasonable overall structural design, it is resistant to high temperatures and corrosion, has stable electrical performance, and high mechanical strength. It is suitable for high-temperature, humid, and corrosive industrial environments, and significantly extends the service life of the power cord. Attached Figure Description

[0025] Figure 1This is a schematic diagram of the overall structure of this utility model;

[0026] Figure 2 This is a schematic diagram of the surface structure of the buffer isolation layer of this utility model;

[0027] Figure 3 This is a schematic diagram of the surface structure of the insulating inner layer of this utility model;

[0028] In the diagram: 1. Conductor core; 2. Insulating inner layer; 3. Functional enhancement layer; 4. Shielding layer; 5. Buffer isolation layer; 6. Corrosion-resistant sheath layer; 7. Silicone rubber; 8. Adhesive layer. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0030] Please see Figure 1-3 This utility model discloses a multi-layer composite high-temperature and corrosion-resistant PVC power cord, comprising, from the inside out:

[0031] Conductor core 1;

[0032] The inner insulating layer 2 is made of high-temperature resistant PVC composite material and wraps around the outside of the conductor core 1.

[0033] The functional enhancement layer 3 is made of a fluorine material thin film layer, which is wrapped around the outside of the functional enhancement layer 3;

[0034] The buffer isolation layer 5 is wrapped around the outside of the functional enhancement layer 3 and is made of glass fiber.

[0035] The corrosion-resistant sheath layer 6 is made of modified PVC composite material and is wrapped around the outside of the buffer isolation layer 5.

[0036] This technical solution achieves both high-temperature resistance and corrosion resistance through complementary functions and synergistic protection among its core layers, from the inside out. The specific principle is as follows:

[0037] Conductor core 1:

[0038] The multi-strand tin-plated copper wire stranded design reduces the skin effect of current and improves conductivity by splitting the current through multiple strands. On the other hand, the stranded structure gives the conductor core 1 good flexibility and avoids the defect of easy breakage of single-strand hard copper wire.

[0039] The tin plating layer provides a physical barrier for the copper wire, isolating it from air, moisture and corrosive media, and preventing the copper wire from oxidizing to form copper oxide, which affects conductivity. The coupling agent coating on the outside of the conductor core 1, such as silane coupling agent KH-550, enhances the interfacial bonding between the conductor core 1 and the outer insulating inner layer 2 through chemical bond bridging, avoiding interlayer peeling caused by high temperature or vibration.

[0040] Insulating inner layer 2:

[0041] High-temperature resistant PVC composite materials made of polyvinyl chloride resin, nano-reinforcing fillers, and heat stabilizers are preferred, among which:

[0042] Polyvinyl chloride (PVC) resin provides basic insulation properties;

[0043] Nanofillers, such as nano-silica, fill the gaps between PVC molecules through a micro-reinforcement effect, improving the material's heat resistance and enhancing its mechanical strength.

[0044] Heat stabilizers, such as organotin stabilizers, inhibit the deHCl reaction of PVC at high temperatures, allowing the inner insulating layer 2 to be used for a long time at 150°C without aging.

[0045] The inner insulating layer 2 tightly wraps the conductor core 1 through an extrusion process, forming a continuous and gapless insulating barrier to ensure electrical safety.

[0046] Functionality Enhancement Layer 3:

[0047] Fluorine-based thin films, such as PTFE and ETFE, contain strong CF bonds in their molecular structure, giving the materials two key properties:

[0048] High temperature resistance: Long-term operating temperature is 150-200℃, and short-term resistance is above 200℃. It can block the transmission of external high temperature to the inner insulation layer 2 and avoid PVC aging due to overheating.

[0049] Chemical inertness: It does not react with corrosive media such as acids, alkalis, and salt spray, and its high molecular density can prevent corrosive media from penetrating into the inner layer, protecting the insulating inner layer 2 and the conductor core 1.

[0050] The film is tightly bonded to the insulating inner layer 2 through a hot melt bonding process, with no gaps between layers, thus preventing the accumulation of moisture or corrosive media between layers.

[0051] Buffer isolation layer 5:

[0052] Made of glass fiber, its inorganic fiber structure has high strength and high temperature resistance, and can be used as a mechanical support skeleton; the strip-like structure achieves full coverage of the functional enhancement layer 3 through spiral winding, avoiding local exposure.

[0053] The silicone rubber 7 is impregnated. The elasticity of the silicone rubber 7 can convert external impact / vibration into elastic deformation, preventing the functional reinforcement layer 3 from cracking due to rigid impact. At the same time, the low thermal conductivity of the silicone rubber 7 can further block external heat and reduce the temperature load of the insulating inner layer 2.

[0054] Corrosion-resistant sheath layer 6:

[0055] Modified PVC composites containing PVC resin, nano-montmorillonite, antioxidants, and UV absorbers are preferred, among which:

[0056] Nano-montmorillonite has a layered structure and is arranged in parallel within the PVC matrix, forming a labyrinthine barrier channel that extends the penetration path of corrosive media such as acids, alkalis, and salt spray.

[0057] Antioxidants, such as hindered phenols 1010, inhibit the oxidative degradation of PVC; UV absorbers, such as benzotriazoles UV-327, absorb ultraviolet rays and prevent the sheath from aging and cracking when used outdoors.

[0058] The sheath layer is wrapped with the buffer isolation layer 5 through an extrusion process. The thickness is 1.5-2.5 times that of the inner insulation layer 2. The thicker sheath layer can improve the resistance to corrosion and wear, while the thinner inner insulation layer 2 can reduce the overall cable flexibility loss while ensuring insulation performance.

[0059] The thickness ratio of the inner insulating layer 2 to the corrosion-resistant sheath layer 6 is 1:1.5-2.5.

[0060] The core requirement for the inner insulation layer 2 is electrical insulation. If it is too thick, it will cause the cable to become stiff and its bending performance to decrease. About 1mm is sufficient to meet the insulation requirements of 0.6 / 1kV level.

[0061] The anti-corrosion sheath layer 6 needs to provide external protection. A thicker layer can extend the penetration time of corrosive media and improve wear resistance. The thickness ratio of the two layers balances electrical performance and protective performance, avoiding performance imbalance caused by a single layer being too thick or too thin.

[0062] The buffer isolation layer 5, with its strip-like structure, can achieve overlapping coverage through spiral winding, avoiding the seam gaps of traditional tubular isolation layers.

[0063] The silicone rubber 7 is impregnated to fill the gaps between the fibers of the glass fiber cloth, forming a dense elastic layer. On the one hand, it improves the waterproofness, and on the other hand, it absorbs impacts through elastic deformation, such as drop impacts, to prevent the film from breaking.

[0064] The adhesive layer 8 between the insulating inner layer 2 and the functional reinforcement layer 3 is preferably made of EVA hot melt adhesive. After the EVA hot melt adhesive melts, it fills the micro gaps between the insulating inner layer 2 and the functional reinforcement layer 3. After cooling, it forms a tight bond, avoiding interlayer lifting caused by changes in ambient humidity. Lifting will form air gaps, and air expansion at high temperatures can easily lead to interlayer cracking. At the same time, it further blocks the path of moisture penetration.

[0065] The shielding layer 4 between the functional enhancement layer 3 and the buffer isolation layer 5 is preferably made of copper strip or aluminum-plastic strip. It forms a continuous conductive layer by wrapping or longitudinally wrapping. It uses the principle of electromagnetic induction to induce external electromagnetic interference into eddy currents, and then releases them through grounding to achieve electromagnetic shielding. At the same time, the metal strip can help block ultraviolet rays and high-frequency heat, further protecting the inner structure. It is suitable for power supply scenarios of precision equipment, such as industrial sensors and medical equipment.

[0066] Detailed Workflow Summary

[0067] Manufacturing process flow

[0068] Step 1: Preparation of conductor core 1

[0069] Select tin-plated copper wire and twist it according to the designed number of strands, such as 7 strands or 19 strands. Control the twisting pitch to be 10-15 times the diameter of conductor core 1. For example, if the diameter of conductor core 1 is 1mm, the pitch should be 10-15mm.

[0070] A coupling agent coating is applied to the outside of the stranded conductor core 1 using a roller coating process, and then dried in an oven at 60-80℃ to enhance the bonding force with the inner insulating layer 2.

[0071] Step 2: Extrusion and coating of the inner insulating layer 2

[0072] Preparation of high-temperature resistant PVC composite material: Polyvinyl chloride resin, nano silica and organotin stabilizer are mixed in a mass ratio of 100:5-10:2-5, and then melt-mixed in a twin-screw extruder to form granules;

[0073] A single-screw extruder is used to extrude the composite material onto the outside of the conductor core 1. The thickness of the inner insulation layer 2 is controlled by a sizing sleeve, and the insulation layer is cooled and shaped in a cooling water tank to ensure that the insulation layer is continuous and free of air bubbles.

[0074] Step 3: Apply adhesive layer 8 and bond it to functional reinforcement layer 3.

[0075] EVA hot melt adhesive was applied to the outer side of the inner insulation layer 2 using a hot melt adhesive coating machine, while maintaining the coating temperature at 120-140℃.

[0076] The fluorine material film is tightly bonded to the outside of the adhesive layer 8 using a hot melt laminator, ensuring that the film is wrinkle-free and gap-free. After bonding, it is allowed to cool naturally to room temperature.

[0077] Step 4: Preparation of shielding layer 4

[0078] Select copper strip or aluminum-plastic strip and spirally wrap it around the outside of the functional enhancement layer 3 with a coverage of 90-95% using a wrapping machine, or longitudinally wrap it and then weld / bond the seams to form a continuous shielding layer 4.

[0079] Step 5: Wrap the buffer isolation layer 5

[0080] Select fiberglass strips, first dip them in silicone rubber solution 7, and then dry and cure them at 120-150℃;

[0081] The strip-shaped buffer isolation layer 5 is spirally wound onto the outside of the shielding layer 4 with an overlap rate of more than 50% using a winding machine.

[0082] Step 6: Extrusion and coating of the anti-corrosion sheath layer 6

[0083] Preparation of modified PVC composite materials: Polyvinyl chloride resin, nano-montmorillonite, antioxidant, and ultraviolet absorber are mixed in a mass ratio of 100:3-8:0.5-1:0.3-0.8 and melt-blended using a twin-screw extruder;

[0084] The composite material is extruded and coated on the outside of the buffer isolation layer 5 using a single screw extruder. The thickness of the anti-corrosion sheath layer 6 is controlled to be 1.5-2.5 times that of the insulating inner layer 2. For example, if the insulation is 1mm thick, the anti-corrosion sheath layer 6 is 1.5-2.5mm thick. After being cooled and shaped in a cooling water tank, it is wound into a coil.

[0085] Step 7: Finished Product Inspection

[0086] Electrical performance testing: Testing insulation resistance and withstand voltage;

[0087] Environmental performance testing: high-temperature aging, salt spray test;

[0088] Mechanical performance testing: bending test, tensile test.

[0089] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-temperature resistant and corrosion-resistant PVC power cord with a multi-layer composite structure, characterized in that, Including the following, arranged sequentially from the inside out: Conductor core (1); The inner insulating layer (2) is made of high-temperature resistant PVC composite material and is wrapped around the outside of the conductor core (1); The functional enhancement layer (3) is made of a fluorine material thin film layer and wrapped around the outside of the functional enhancement layer (3); A buffer isolation layer (5) is wrapped around the outside of the functional enhancement layer (3) and is made of glass fiber. The corrosion-resistant sheath layer (6) is made of modified PVC composite material and is wrapped around the outside of the buffer isolation layer (5).

2. The high-temperature resistant and corrosion-resistant PVC power cord with a multi-layer composite structure according to claim 1, characterized in that, The thickness ratio of the insulating inner layer (2) to the anti-corrosion sheath layer (6) is 1:1.5-2.

5.

3. The high-temperature resistant and corrosion-resistant PVC power cord with a multi-layer composite structure according to claim 1, characterized in that, The conductor core (1) comprises multiple strands of tin-plated copper wires, which are twisted together, and the outer side of the conductor core (1) is coated with a coupling agent coating.

4. The high-temperature resistant and corrosion-resistant PVC power cord with a multi-layer composite structure according to claim 1, characterized in that, The buffer isolation layer (5) has a strip-like structure, and silicone rubber (7) is impregnated on the buffer isolation layer (5).

5. The high-temperature resistant and corrosion-resistant PVC power cord with a multi-layer composite structure according to claim 1, characterized in that, An adhesive layer (8) is provided between the insulating inner layer (2) and the functional enhancement layer (3), and the adhesive layer (8) is made of hot melt adhesive.

6. The high-temperature resistant and corrosion-resistant PVC power cord with a multi-layer composite structure according to claim 1, characterized in that, A shielding layer (4) is provided between the functional enhancement layer (3) and the buffer isolation layer (5), and the shielding layer (4) is a copper strip or an aluminum-plastic strip.

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