NANO-doped cable and NANO-doped cable production method

Abstract

In particular, the invention relates to a nano-doped cable structure that provides physical resistance against factors such as heat, humidity, impact, combustion and chemical factors while maintaining mechanical properties such as flexibility, tensile / tear strength and at the same time improving insulation properties, especially in cables that provide electricity and / or signal conduction by using organic and nano-sized material additives, and a nano-doped cable production method that enables to obtain this cable structure.

Description

[0001] NANO-DOPED CABLE AND NANO-DOPED CABLE PRODUCTION METHOD

[0002] Technical Field

[0003] The invention relates to a nano-doped cable and its manufacturing method for improving insulation, physical durability and conduction efficiency while maintaining the flexibility properties of the cable structure.

[0004] In particular, the invention relates to a nano-doped cable structure that provides physical resistance against factors such as heat, humidity, impact, combustion and chemical factors while maintaining mechanical properties such as flexibility, tensile / tear strength and at the same time improving insulation properties, especially in cables that provide electricity and / or signal conduction by using organic and nano-sized material additives, and a nano-doped cable production method that enables to obtain this cable structure.

[0005] State of the Art

[0006] In power cables providing electricity conduction and signal cables providing data conduction, the conduction performance of the cables is required to be high and there is no loss of conduction performance during the period of use. Therefore, it is aimed to have high physical strength and insulation properties of the insulation and protection layers surrounding the conduction line within the cable and at the same time to allow a certain amount of flexibility according to the usage area. Although there are many different types of materials used for this purpose, production costs increase as the durability and insulation effectiveness of the materials in question increases. Due to the large number of areas where electrical or signal conduction is needed, it is necessary to produce a large amount of cables of different properties, lengths and types, and production costs must be kept within a certain limit due to the large amount of cables produced. Hence, Polyvinyl Chloride (PVC), which has a lower cost compared to other materials, is generally preferred as a polymeric raw material for obtaining the insulation and filling material in the cable structure, but the efficiency and durability of the cables obtained with this material are low. Materials such as Halogen-Free Flame Retardant (HFFR) or Crosslinked Polyethylene (XLPE), which have higher durability and / or insulation properties than PVC, allow the production of more efficient cables, but when binding and supporting chemical additives are considered, costs increase considerably. In the current technique, certain amounts of calcite and reinforcing chemical materials are added to PVC during production to increase cable strength without increasing costs too much. However, while these added materials create negative effects on the environment and human health, they are not sufficient to increase the usage efficiency of the cable.

[0007] Crosslinked Polyethylene (XLPE) cables contain polymers that prevent melting and separation at high temperatures in different polyethylene chains that are cross-linked to each other. Hence, XLPE is suitable for use in systems operating at high temperatures, but it has higher dielectric losses compared to Polyethylene (PE). It has high resistance to aging and water treeing and the general operating temperature is between 90-110°C. Ethylene Propylene Rubber (TPU), another outer layer material, is a copolymer of ethylene and propylene and is more flexible than PE and XLPE, but has higher dielectric losses. Polyurethane (PUR) has a general operating temperature of (-)50-90°C and has a flexible structure even at low temperatures and provides good resistance to chemicals and moisture, but it is not suitable for use in systems operating at high temperatures. Therefore, it is aimed to ensure that the outer layer used in power cables has high resistance to high temperatures and to reduce dielectric losses. However, while the use of these materials does not provide sufficient strength, the production cost increases significantly with the other chemical components used with these materials. Artificial and / or chemical additives used to improve the properties in question prevent the power cable from being recycled after use, and threaten human and environmental health by causing the release of various hazardous gases into the environment in the event of a possible fire.

[0008] A patent document numbered CN105968592A, which is in the state of the art, describes a flame retardant cable sheath granule paint (masterbach) and a preparation method. Flame retardant cable sheath is prepared by weight from polybutylene resin, polytetrafluoroethylene, polyimide, polyethylene terephthalate, vinyl distearamide, oil sands bitumen, flash powder, shell powder, calcined bentonite, zinc oxide, polysulfonyldiphenylene phenyl phosphonate, a methyl chloride. Acrylic acid-butadiene-styrene copolymer, active calcium carbonate, nano aluminum powder, rare earth stabilizer, composite flame retardant and silane coupling agent are used in the mixture. Flame retardant cable sheath masterbatch, prepared with appropriate material selection and ratio, has high flame retardancy, high insulation and mechanical strength, and aims to shorten the preparation process and resist high temperatures. The document mentioned does not mention a cable structure and production method that improves flexibility, insulation and physical durability, especially by using organic and nano-sized material additives.

[0009] In another patent document numbered CN111662495A, which is the state of the art, scratchresistant, low-smoke, halogen-free, flame retardant polyolefin cable material is described. The cable material in question contains 30-50 parts / share EVA, 50-70 parts HDPE, 15-25 parts LDPE, 90-120 parts flame retardant, 8-12 parts compatibilizer, 1-2 parts compounding agent, 0.5-0.8 parts antioxidant and 0.5-1.0 parts lubricant. The lubricant is prepared by mixing modified silicone masterbach, stearic acid and erucamide. With the related material, it is aimed to obtain scratch-resistant, low-smoke, halogen-free flame retardant polyolefin cable material. The document mentioned does not mention a cable structure and production method that improves flexibility, insulation and physical durability, especially by using organic and nanosized material additives.

[0010] In conclusion, it relates to a nano-doped cable structure that enables the cable to increase its physical resistance against damaging factors such as heat, humidity, impact, combustion and chemicals and its electrical and / or signal conduction efficiency while maintaining its flexibility properties and at the same time improving its insulation properties by using organic and nanosized material additives, and a nano-doped cable production method that enables obtaining this cable structure.

[0011] Purpose of the Invention

[0012] The present invention relates to a nano-doped cable and nano-doped cable production method that meets the above-mentioned requirements, eliminates possible disadvantages and provides some additional advantages.

[0013] The main purpose of the nano-doped cable and manufacturing method subject to the invention is to obtain a nano-doped cable and production method that is suitable for use in electrical and / or signal conduction, using waste organic and nano-sized material, improving mechanical properties such as flexibility, tensile, yield strength and insulation properties, increasing physical resistance against damaging factors such as heat, moisture, impact, combustion and chemicals, and increasing electrical and / or signal conduction efficiency.

[0014] Another aim of the invention is to obtain an efficient nano-doped cable and production method that enables the recycling of organic waste and the reduction of production costs by using waste materials.

[0015] Another aim of the invention is to obtain an effective nano-doped cable and production method that reduces the dielectric loss on the cable and increases electrical insulation.

[0016] Another aim of the invention is to obtain a nano-doped cable and manufacturing method that increases the cable's lifespan and recycling efficiency. Another aim of the invention is to obtain a functional nano-doped cable and production method that increases the effectiveness of the cable in abrasion and cutting resistance, ultraviolet light and temperature resistance, chemical and alkaline resistance, and mold resistance.

[0017] Another aim of the invention is to obtain a nano-doped cable and manufacturing method that improves the flame retardant and antibacterial properties of the cable.

[0018] Another aim of the invention is to obtain a nano-doped cable and manufacturing method that reduces toxic gases released into the environment in case of fire and protects human and environmental health.

[0019] Another aim of the invention is to obtain a nano-doped cable and manufacturing method that prevents iron oxide formation during and / or after production and prevents structure and color deterioration of the cable.

[0020] Another aim of the invention is to obtain a nano-doped cable and manufacturing method that enables the antimicrobial properties of snails and seashells to be activated by the sintering process during production.

[0021] In order to achieve the above objectives in the most general form, the nano-doped cable, which includes at least one conduction layer, improves mechanical properties such as flexibility, tensile and yield strength, and increases resistance / durability against external influences such as ultraviolet light, water, heat, combustion, cutting and abrasion, includes at least one insulation layer containing stearic acid coated nano-sized waste seashell and waste snail shell particles; at least one protection layer containing nano-sized waste seashell and waste snail shell particles coated with silane mixture and nano-sized talc powder.

[0022] A method of manufacturing nano-doped cable developed with the present invention, enabling the production of nano-doped cable includes the steps of cleaning and disposing of waste seashells and waste snail shells; grinding the shells and obtaining the nanometre sized powdered shell mixture; spraying stearic acid on the nano-sized particles and performing the first modification process; mixing with the first polymer material in the granule mixer and bringing it to a dough consistency; shredding the dough into granules, then shaping the granules and obtaining the insulation layer; positioning it to surround the conduction layer; adding the silane mixture to the ethyl alcohol solution and mixing, then adding the shell mixture into the solution and continuing the mixing process; completion of the second modification process by filtering, washing and sintering the mud-like mixture; dry mixing process by adding nano-sized talc powder into the shell mixture and mixing it with the second polymer material in the granule mixer to form a dough; shaping the granules and obtaining the protection layer after the dough is shredded into granules; obtaining the nano-doped cable by positioning it in such a way that it surrounds the insulation layer and the conduction layer.

[0023] The structural and characteristic features and all advantages of the invention will be more clearly understood by means of the figures given below and the detailed description written by making references to these figures, and therefore, the evaluation should be made by considering these figures and detailed description.

[0024] Figures to Help Understand the Invention

[0025] To best understand the structure and advantages of the present invention, it should be evaluated together with the figures described below.

[0026] Figure 1 : A front view of the nano-doped cable that is the subject of the invention.

[0027] Figure 2: A cross-sectional view of the nano-doped cable that is the subject of the invention.

[0028] Part References

[0029] 1. Conduction layer

[0030] 2. Insulation layer

[0031] 3. Protection layer

[0032] 4. Filler layer

[0033] A. Nano-doped cable

[0034] Detailed Description of the Invention

[0035] In this detailed description, the preferred embodiments of the nano-doped cable and the manufacturing method are described solely for the purpose of a better understanding of the subject matter and without limitation.

[0036] A nano-doped cable (A), the exemplary appearance of which is shown in Figure 1, developed with the present invention is consists of; for the conduction of electricity, light and / or signals, preferably comprising at least one conduction layer (1) comprising conductive wires or optical wires, improving mechanical properties such as flexibility, tensile and yield strength, and increasing resistance / durability against external influences such as ultraviolet light, water, heat, burning, cutting and abrasion, at least one insulation layer (2), preferably made of Cross-Linked Polyethylene (XLPE) material, containing nano-sized waste seashell and waste snail shell particles, preferably up to 150 nanometers in size, coated with stearic acid, which is positioned to cover the said conduction layer (1), protecting the conduction layer (1) against electrical contact and external influences, increasing the insulation effect and increasing the conduction efficiency; nano-sized waste seashell and waste snail shell particles coated with a silane mixture, preferably comprising gamma-Aminopropyltriethoxysilane (silane 1100) and gamma- Glycidoxypropyltrimethoxysilane (silane A-187), preferably comprising nano-sized talc powder having a size of at most 900 nanometers, positioned to surround said conduction layer (1) and said insulation layer (2), at least one protection layer (3), preferably made of Halogen Free Flame Retardant (HFFR) material, which provides protection of the conduction layer (1) and insulation layer (2) from external influences, increasing physical durability and fire resistance, improving mechanical properties.

[0037] In an exemplary embodiment of the nano-doped cable (A) developed with the present invention, the insulation layer (2) surrounding the conduction layer (1) provides electrical and physical insulation of the conduction layer (1) by means of stearic acid coated nano-sized waste seashell and waste snail shell particles. The stearic acid coating surrounding the shell particles acts as a molecular bridge between the inorganic filler / additives interface and the organic polymer matrix and enhances the electrical and optical insulation properties of nano-sized waste seashell and waste snail shell particles. Thus, the insulation efficiency of the insulation layer (2) increases and the efficiency of signal and / or power conduction transmitted by the conduction layer (1) is increased. The conduction layer (1) and the protection layer (3) surrounding the said insulation layer (2) enable to increase the mechanical properties of the cable, such as flexibility and tensile strength, thanks to the silane mixture coated nano-sized waste seashell and waste snail shell particles and nano-sized talc powders. The silane mixture in this layer strengthens the organic- inorganic material bond formation for both shell particles and talc powders, increasing the physical durability of the cable (A) and providing resistance to cuts, scratches, deterioration and fire.

[0038] In a preferred embodiment of the invention, said nano-doped cable (A) comprises at least one filling layer (4), preferably made of Ethylene Propylene Rubber (TPU), which is positioned between said insulation layer (2) and said protection layer (3), and which protects the position and form of said conduction layer (1), which comprises nano-sized particles of waste seashells and waste snail shells, against impact, bending, crushing, crimping, curling and cutting. A nano-doped cable production method developed with the present invention, which enables the production of nano-doped cable (A) that improves mechanical properties such as flexibility, tensile and yield strength, and increases resistance / durability against external influences such as ultraviolet light, water, heat, combustion, cutting and abrasion, includes the steps of cleaning of waste seashells and waste snail shells using acetone and preferably sterilized by means of an oven and dried at a temperature of 200-300 °C; grinding of the dried waste seashells and waste snail shells and converting them into nanometer-sized particles to obtain a powdered shell mixture; taking a first volume of shell mixture for the first modification process and spraying stearic acid on the nano-sized particles in the mixture and performing the first modification process by coating the particles with stearic acid; mixing the shell mixture containing the modified nano-sized particles with the first polymer material, preferably made of Crosslinked Polyethylene (XLPE) material, in a granule mixer and bringing it to a dough consistency; the obtained dough is crushed into granules and then extruded to form said granules and to obtain said insulation layer (2), preferably containing at most 40% by volume of the shell mixture; said insulation layer (2) is positioned so as to surround said conduction layer (1); for the second modification process, taking a second volume amount of the shell mixture, preferably a silane mixture comprising gamma-Aminopropyltriethoxysilane (silane 1100) and gamma- Glycidoxypropyltrimethoxysilane (silane A-187), which by volume is 1-3% of said second volume value, Adding ethyl alcohol solution, preferably with a solution ratio of 10-70% and a volume of 200-500 milliliters, and stirring, preferably by means of a magnetic stirrer, then adding the shell mixture into the solution and continuing the stirring process; completing the second modification process by filtering the mud-like mixture obtained by mixing, preferably for 24 hours, washing with distilled water and sintering preferably in an oven at a temperature of 300- 1200 °C using hydrogen gas; dry mixing process by adding nano-sized talc powder into the shell mixture containing the modified nano-sized particles and mixing with the second polymer material, preferably made of Halogen Free Flame Retardant (HFFR) material, in a granule mixer and bringing it to a paste consistency; forming said granules by applying extrusion process after crushing the obtained dough into granules and preferably obtaining said protection layer (3) containing at most 40% by volume of shell mixture and at most 10% of talc powder; obtaining nano-doped cable (A) by positioning said protection layer (3) so as to surround said insulation layer (2) and said conduction layer (1).

[0039] In a preferred embodiment of the invention, the method of manufacturing said nano-doped cable comprises the steps of adding ATH, MDH, EVA, silane 6300, UV stabilizer, titanate, maleic, DOTP, soy, silicone, silicone oil, polyolefin, starin, paraffin, antioxidant 1076, hydrogen peroxide and / or polyolefin matrix to the mixture during mixing in a granule mixer. In a preferred embodiment of the invention, the method of manufacturing said nano-doped cable comprises the steps of; after obtaining the mentioned insulation layer (2), the shell mixture containing nano-sized particles modified by the first modification process is mixed with the third polymer material, preferably made of Ethylene Propylene Rubber (TPU), in a granule mixer and brought to a paste consistency; forming said granules by applying an extrusion process after crushing the obtained dough into granules and preferably obtaining said filling layer (4) containing a shell mixture of up to 40% by volume; positioning said filler layer (3) so that it is between said insulation layer (2) and said protection layer (3).

[0040] Thanks to the nano-doped cable and production method developed by the present invention, organic and nano-sized material additives are used to maintain the flexibility properties of the cable (A) and at the same time improve its insulation properties. Moreover, waste snail and shell powders have a ceramic-like structure, which improves the stiffness, bending properties and dielectric properties of the reinforced plastics, and flame retardant, a molecular structure that chemically or physically inhibits the growth of flame. Nano-sized talc powders, on the other hand, have very low particle sizes, resulting in ultra-layered properties that provide exceptional hardness / impact, superior scratch and distortion resistance, and improved crystallization. Thus, a nano-doped cable (A) that provides physical resistance against damaging factors such as heat, humidity, impact, combustion and chemicals, and electrical and / or signal conduction efficiency, and a nano-doped cable production method that enables the production of this cable are obtained.

Claims

CLAIMS1. A nano-doped cable (A) which comprises at least one conduction layer (1) that provides electricity, light and I or signal conduction, improves mechanical properties such as flexibility, tensile and yield strength, and increases resistance I durability against external influences such as ultraviolet light, water, heat, burning, cutting and abrasion, comprising: at least one insulation layer, wherein the insulation layer comprises stearic acid- coated nano-sized waste seashell and waste snail shell particles, positioned to cover the said conduction layer (1), which protects the conduction layer (1) against electrical contact and external influences, and increases the insulation effect and increasing the conduction efficiency; at least one protection layer (3), which is positioned to surround the perimeter of the conduction layer (1) and the insulation layer (2), wherein the protection layer (3) comprises nano-sized waste seashell and waste snail shell particles coated with silane mixture and nano-sized talc powder, which protects the conduction layer (1) and insulation layer (2) from said external influences, and increases physical durability and fire resistance, and improves mechanical properties.

2. A nano-doped cable (A) according to Claim 1, wherein the conduction layer (1) comprises conductive wire or optical wire.

3. A nano-doped cable (A) according to Claim 1 , wherein the waste seashell and waste snail shell particles are at most 150 nanometers in size.

4. A nano-doped cable (A) according to Claim 1 , wherein the insulation layer (2) is made of Crosslinked Polyethylene (XLPE) material.

5. A nano-doped cable (A) according to Claim 1 , wherein the silane mixture contains gamma- Aminopropyltriethoxysilane (Silane 1100) and gamma-Glycidoxypropyltrimethoxysilane (silane A-187).

6. A nano-doped cable (A) according to Claim 1 , wherein the talc powder particles are at most 900 nanometers in size.

7. A nano-doped cable (A) according to Claim 1, wherein the protection layer (3) is made of Halogen Free Flame Retardant (HFFR) material.

8. A nano-doped cable (A) according to Claim 1, wherein the cable (A) also comprises at least one filling layer (4), which is positioned between said insulation layer (2) and said protection layer (3), and preferably made of Ethylene Propylene Rubber (TPU) material, preferably made of Ethylene Propylene Rubber (TPU) material, wherein the filling layer (4) comprises nano-sized waste seashell and waste snail shell particles, and protects the position and form of said conduction layer (1) against impacts, bending, crushing, curling and cutting.

9. A method of producing a nano-doped cable, wherein the nano-doped cable is obtained according to claim 1, comprising the steps of: cleaning waste seashells and waste snail shells by using acetone then drying them; obtaining the powdered shell mixture by grinding the dried waste seashells and waste snail shells and converting them into nanometer-sized particles; taking a first volume of the shell mixture for the first modification process and performing the first modification process by spraying stearic acid on the nano-sized particles in the mixture and coating the particles with the stearic acid; mixing the shell mixture containing the modified nano-sized particles with a first polymer material in the granule mixer and bringing it to a dough consistency; forming the said granules by applying the extrusion process and obtaining the said insulation layer (2) after breaking the resulting dough into granules; positioning the obtained insulation layer (2) so that it surrounds the said conduction layer (1); taking a second volume of shell mixture, performing the first modification process by adding the silane mixture of 1-3% of the said second volume value by volume to the ethyl alcohol solution and stirring, then adding the shell mixture into the solution and continuing the stirring process; filtering the slurry-like mixture obtained by mixing process, washing the mixture with distilled water and sintering using hydrogen gas, and completing the second modification process; adding nano-sized talc powder into the shell mixture containing the modified nanosized particles for dry mixing process and mixing it with a second polymer material in a granule mixer and bringing it to a dough consistency;forming the granules by applying the extrusion process and obtaining the protection layer (3) after breaking the resulting dough into granules; obtaining the nano-doped cable (A) by positioning said protection layer (3) so as to surround said insulation layer (2) and said conduction layer (1).

10. A nano-doped cable production method according to Claim 9, wherein carrying out the drying process with sterilization by means of an oven and at a temperature of 200-300 °C.

11. A nano-doped cable production method according to Claim 9, wherein the first polymer material is made of Crosslinked Polyethylene (XLPE).

12. A nano-doped cable production method according to Claim 9, wherein the insulation layer(2) containing a shell mixture of not more than 40% by volume.

13. A nano-doped cable production method according to Claim 9, wherein the silane mixture containing gamma-Aminopropyltriethoxysilane (Silane 1100) and gamma- Glycidoxypropyltrimethoxysilane (silane A-187)..

14. A nano-doped cable production method according to Claim 9, wherein the ethyl alcohol solution comprising 10-70% solution ratio and 200-500 milliliters volume.

15. A nano-doped cable production method according to Claim 9, comprising the step of performing the mixing process by means of a magnetic stirrer.

16. A nano-doped cable production method according to Claim 9 comprising the step of filtering the sludge-like mixture for 24 hours by resting it.

17. A nano-doped cable production method according to Claim 9, wherein the second polymer material is made of Halogen Free Flame Retardant (HFFR) material.

18. A nano-doped cable production method according to Claim 9, wherein the protection layer(3) comprising less than 40% of shell mixture and less 10% talc powder by volume.

19. A nano-doped cable production method according to Claim 9, comprising the step of adding ATH, MDH, EVA, silane 6300, UV stabilizer, titanate, maleic, DOTP, soy, silicone, silicone oil, polyolefin, starin, paraffin, antioxidant 1076 and / or hydrogen peroxide to the mixture during the mixing process in the granule mixer.

20. A nano-doped cable production method according to Claim 9, comprising the further steps of mixing the shell mixture containing nano-sized particles modified by the first modification process with the third polymer material in the granule mixer, wherein the third polymer material is preferably made of Ethylene Propylene Rubber (TPU), and bringing it to a dough consistency after obtaining the insulation layer (2); forming said granules by applying an extrusion process after crushing the dough into granules and obtaining said filling layer (4) preferably containing a shell mixture of up to 40% by volume; positioning said filler layer (3) so that it is between the insulation layer (2) and the protection layer (3).

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