Reinforced cable structure and production method

Abstract

In particular, the invention relates to a reinforced cable structure which enables to increase the electricity and / or signal conduction efficiency and prevent energy loss without increasing the cross-sectional area of the conduction layer of the cable, to improve the mechanical and thermal properties of the protective layer of the cable, to increase its resistance to physical, ultraviolet radiation, liquid absorption, temperature and flammability by using graphene material in cables providing electricity and / or signal conduction, and to a reinforced cable structure production method for obtaining this cable structure.

Description

[0001] REINFORCED CABLE STRUCTURE AND PRODUCTION METHOD

[0002] Technical Field

[0003] The invention relates to a reinforced cable structure and production method for improving the mechanical properties of a conduction cable, increasing its conductive efficiency, physical and fire resistance.

[0004] In particular, the invention relates to a reinforced cable structure which enables to increase the electricity and / or signal conduction efficiency and prevent energy loss without increasing the cross-sectional area of the conduction layer of the cable, to improve the mechanical and thermal properties of the protective layer of the cable, to increase its resistance to physical, ultraviolet radiation, liquid absorption, temperature and flammability by using graphene material in cables providing electricity and / or signal conduction, and to a reinforced cable structure production method for obtaining this cable structure.

[0005] State of the Art

[0006] In cables that provide electricity and / or signal conduction, energy conduction is carried out by the conduction layer extending in the center of the cable and there is a protective layer surrounding the conduction layer to protect this layer from external influences and to prevent energy loss or interruption. Copper material is preferred as the conductor material of power cables that provide electricity conduction due to its high conductivity, mechanical strength, melting temperature and heat dissipation. However, due to the high cost and specific gravity of copper material, aluminum material, which has both lower cost and weight than copper, is used in areas that require high volume production and lightweight cable structure. However, due to the low conductivity efficiency of aluminum compared to copper, the cross-sectional area needs to be about 60% more than copper in order to provide conduction close to copper. This leads to an increase in aluminum wire thickness to increase the conductivity value, while limiting heat dissipation due to its low thermal conductivity compared to copper, causing hot spots to form in the cable and causing negative situations such as fire, energy loss, cable and environmental damage. In addition, due to the lower melting temperature of aluminum compared to copper, its resistance to overloads is low and this limits its use considerably. For this reason, it is necessary to increase the electrical and thermal conductivity of the conductive layer, which is made of a material with low cost but insufficient electrical conduction properties, especially aluminum. In current applications and research, Graphene is known to exhibit superior load-bearing mobility and thermal properties in addition to superior mechanical properties (Young's modulus = 1 TPa, intrinsic tensile strength = 130 GPa). These properties make graphene an attractive filling material for metal matrix composites (Table-1). However, some difficulties arise especially in the processes of adding graphene material to the cable layers and then giving the cable form. In particular, it is important that the graphene material is homogeneously distributed in the structure, does not have a negative effect on the adhesion efficiency and conductivity with the metal.

[0007] Table-1 : Conductivity Values Comparison Table

[0008] A patent document CN104194585A, which is in the state of the art, describes a graphene- modified resin powder coating and manufacturing process. The graphene-modified resin powder coating contains the following components in weight percent: 50-80 percent resin, 0-40 percent filler, 5-7 percent auxiliary, 0.2-3 percent pigment and 0.005-30 percent graphene. Graphene is added to the graphene-modified resin powder provided by the invention in an amount suitable for conventional resin powder coating. This ensures mechanical properties, conductivity, thermal conductivity, flame resistance, corrosion resistance and weather resistance. The document in question does not mention a solution method for increasing the electrical and / or signal conduction efficiency without increasing the cross-sectional area of the conduction layer of the cable that provides electrical and / or signal conduction by using graphene and increasing the durability of the protective layer of the cable by improving its mechanical and thermal properties.

[0009] Another patent document CN113057636A of the state of the art discloses an anti-interference graphite electrocardioelectrode and a method of preparation. In the mentioned electrocardioelectrode preparation, reduced graphene oxide is first prepared, reduced graphene oxide is combined with polyurethane resin, graphene is surface treated with gammaaminopropyltriethoxysilane, hydroxyl is added and graphene reacts with isocyanate in the polyurethane resin to form cross-linking. Thus, the conductivity of the fiber membrane is improved and a reduced layer of graphene oxide is sprayed on the surface of the fiber membrane, creating a large number of conductive channels and efficient transport of electrons. Thus, by ensuring that the impedance of human skin and graphene is higher, the impedance of the membrane combined with the reduced graphene oxide layer by the multilayer fiber membrane is reduced and the antiinterference capacity of the electrode is improved. In this way, the prepared electrocardioelectrode has good conductivity and anti-interference performance and reduces skin contact impedance. The document in question does not mention a solution method for increasing the electrical and / or signal conduction efficiency without increasing the cross-sectional area of the conduction layer of the cable that provides electrical and / or signal conduction by using graphene and increasing the durability of the protective layer of the cable by improving its mechanical and thermal properties.

[0010] As a result, there is a need for the development of a reinforced cable structure and a reinforced cable production method that enables the development of a reinforced cable structure and a reinforced cable production method that enables the development of a reinforced cable structure that enables the increase of conduction efficiency and prevention of energy loss without increasing the cross-sectional area of the conduction layer of the cable by using graphene material in the cable structure, as well as improving the mechanical and thermal properties of the protective layer of the cable, increasing its resistance to physical, ultraviolet radiation, liquid absorption, temperature and flammability.

[0011] Purpose of the Invention

[0012] The present invention relates to a reinforced cable structure and a method of producing the reinforced cable structure, which fulfills the above-mentioned requirements, eliminates possible disadvantages and provides some additional advantages.

[0013] The main purpose of the reinforced cable structure and production method subject to the invention is to obtain a reinforced cable structure and production method by using graphene material in the cable structure, which increases the conduction efficiency and prevents energy loss without increasing the cross-sectional area of the conduction layer of the cable and improves the mechanical and thermal resistance properties of the protective layer of the cable.

[0014] Another aim of the invention is to obtain an efficient reinforced cable structure and production method that increases the resistance of the cable structure to physical effects, ultraviolet light, liquid absorption, chemicals, temperature and flammability.

[0015] Another aim of the invention is to obtain a safe reinforced cable structure and production method that provides homogeneous distribution in the coating and / or doping process, increasing both conductivity and mechanical strength properties along the entire cable and preventing local heating problem by increasing heat dissipation / removal efficiency. A further object of the invention is to provide an effective reinforced cable structure and production method which prevents the diffusion of carbide phases into the conduction layer, thereby preserving the purity of the metal in the conduction layer and preventing a decrease in its conductivity.

[0016] Another object of the invention is to obtain a functional reinforced cable structure and production method that prevents the formation of agglomeration during graphene application by preventing possible foreign substances from entering the process.

[0017] Another aim of the invention is to obtain a reinforced cable structure and production method that increases the effectiveness of protection against temperature and fire by preserving the temperature resistance of graphene during graphene application.

[0018] Another aim of the invention is to obtain a reinforced cable structure and production method that increases operating and usage efficiency while reducing production costs.

[0019] Another aim of the invention is to obtain a reinforced cable structure and production method that increases both the resistance to tearing, separation, rupture and insulation efficiency by filling the micro cracks and gaps formed in the protective layer.

[0020] Another aim of the invention is to obtain a reinforced cable structure and production method that increases the gas barrier property of the polymer, protects the cable structure against oxidation, corrosion and aging, and reduces the cable structure's lifespan and maintenance / repair costs.

[0021] To achieve the above objectives in their most general form, it involves a reinforced cable structure containing at least one conduction layer, increasing conduction efficiency and preventing energy loss, improving mechanical, chemical, optical, thermal resistance and heat removal properties, at least one reinforcement layer containing nano-sized graphene particles coated with at least one conductive capsule material, covering the surface of the conduction layer, preventing energy loss on the surface, increasing the total conductivity value without changing the cross-sectional area I diameter value of the conduction layer; at least one protection layer made of polymer material containing nano-sized graphene particles, protecting the conduction layer and reinforcement layer, removing the heat generated in the conduction layer, increasing the yield and tensile strength of the cable structure.

[0022] The method of producing the reinforced cable structure developed by the present invention involves the steps of grinding graphite material by adding ice and obtaining graphene particles; sonication of graphene particles in ethanol; obtaining graphene oxide by processing in an oxidizing solution containing nitric acid and pure; sensitizing the graphene oxide in a water bath and making the graphene surface ready for the coating / encapsulation process in the water bath for activation; adding the activated graphene particles into the coating solution containing the conductive capsule material and encapsulating the graphene particles by completely covering them with the conductive capsule material; mixing the encapsulated graphene particles with polyaniline solution and coating the mixture on the conduction layer using chemical vapour deposition method to obtain the reinforcement layer; mixing the raw material mixture containing at least one polymer material and converting it into granule form; melting the granules obtained and adding graphene particles and giving form after mixing and obtaining the protection layer; positioning the protection layer to surround the reinforcement layer and obtaining the cable structure.

[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 perspective view of the reinforced cable structure.

[0027] Part References

[0028] 1 . Conduction layer

[0029] 2. Reinforcement layer

[0030] 3. Protection layer

[0031] 4. Insulation layer

[0032] A. Reinforced cable structure

[0033] Detailed Description of the Invention In this detailed description, the preferred embodiments of the reinforced cable structure and production method subject to invention are described solely for the purpose of a better understanding of the subject matter and without limitation.

[0034] It involves the reinforced cable structure (A), the exemplary view of which is given in Figure 1 , developed with the present invention, comprising at least one conduction layer (1) made of conductive material, preferably copper or aluminium, for the conduction of electricity and / or signals, for increasing the conduction efficiency and preventing energy loss, for improving mechanical, chemical, optical, thermal resistance and heat removal properties, preferably silver, copper, polyaniline (PANI) doped, preferably silver, copper, preferably copper, positioned to surround the conductive layer (1), includes at least one reinforcement layer (2), which is nickel, gold and / or palladium, coated with at least one conductive capsule material that enables the formation of an interfacial bond between graphene and the conduction layer (1), preferably 50- 150 nanometers in size, containing nano-sized graphene particles, covering the surface by adhering to the surface around the extension axis of the conduction layer (1), preventing energy loss on the surface and increasing the total conductivity value without changing the cross- sectional area I diameter value of the conduction layer (1); protection of the conduction layer (1) and the reinforcement layer (2) from physical and chemical external influences, fire and moisture, preferably made of polymer material containing nano-sized graphene particles, preferably 100- 300 nanometers in size, positioned to surround the reinforcement layer (2), at least one protection layer (3), preferably containing Polyvinyl Chloride (PVC), Thermoplastic Polyurethane (TPU), Halogen-Free Flame Retardant (HFFR), Cross-Linked Polyethylene (XLPE) and / or Polyethylene (PE), which allows the heat generated in the conduction layer (1) to be removed and the yield and tensile strength of the cable structure (A) to be increased.

[0035] In an exemplary embodiment of the reinforced cable structure (A) of the present invention, the reinforcement layer (2) covers the conduction layer (1) by adhering to the surface surrounding the axis of extension of the conduction layer (1). Thus, while energy loss from the surface of the conduction layer (1) is prevented, also, the conductivity of graphene particles in the reinforcement layer (1), coated with polyaniline (PANI) doped conductive capsule material, increases the conductivity efficiency without any increase in the diameter value of the conduction layer (1) and also provides insulation. The conductive capsule material in the reinforcement layer (2), in addition to forming an interfacial bond, prevents the formation of the degraded AI4C3 phase and the diffusion of carbide phases into the metal, thus preventing the metal purity and conductivity values of the conduction layer (1) from decreasing. Through the structure of the protection layer (3) wrapped on the reinforcement layer (2) made of polymer material containing nano-sized graphene particles, the mechanical strength and flexibility properties of the cable structure (A) are increased. Through the nano-sized graphene particles filling and closing the cracks and gaps formed on the polymer, the flexible structure of the protection layer (3) is preserved and protection is provided against physical, chemical and liquid material effects applied externally. Also, while increasing the flame resistance of the cable structure (A), the heat generated in the conduction layer (1) is discharged to the outside and the cable (A) is prevented from heating up and reducing the conduction efficiency or localized damage.

[0036] In a preferred embodiment of the invention, the reinforced cable structure (A) is positioned between the reinforcement layer (2) and the protection layer (3), preferably with a thickness value of 0.5-1.5 millimeters on the axis perpendicular to the axis of extension of the conduction layer (1), at least one insulating layer (4) made of polymer material, preferably Thermoplastic Polyurethane (TPU) and / or Polyvinyl Chloride (PVC), which protects the position and form of the layer (1 , 2) of the conduction and reinforcement layers against impact, bending, crushing, curling and cutting.

[0037] The reinforced cable structure production method developed with the present invention, which enables to obtain a reinforced cable structure (A) containing at least one conduction layer (1) providing electrical and / or signal conduction, increasing conduction efficiency and preventing energy loss, improving mechanical, chemical, optical, thermal resistance and heat removal properties involves the steps of adding ice into the graphite material and preferably grinding it using a ball mill and obtaining graphene particles; sonication of graphene particles in ethanol, preferably for 80-100 minutes; obtaining graphene oxide by treating graphene in an oxidizing solution containing 15% mass fraction nitric acid and purified water, preferably for 80- 100 minutes at 60-80 °C, to remove impurities and incorporate hydrophilic groups on its surface; sensitization of graphene oxide by adding 0.1 M SnCI2 in a water bath at 40-60 °C, preferably for 20-40 minutes, to prevent the formation of agglomerates and to separate the surface from impurities, and then activation of the graphene surface by adding 0.1 M PdCI2 solution, preferably in a water bath at 50 °C, to make the graphene surface ready for the coating / encapsulation process; increasing the anti-caking efficiency by applying sonication process, preferably in combination with activation and sensitization processes; repeatedly adding the activated graphene particles into the coating solution containing conductive capsule material, preferably at 75-95 °C, preferably with a pH value of 12, preferably for 5 seconds, 1 minute, 3 minutes, 5 minutes, respectively, and encapsulating the graphene particles by completely covering them with conductive capsule material; obtaining the reinforcement layer (2) by mixing encapsulated graphene particles with polyaniline (PANI) solution and coating the resulting mixture on the conduction layer (1) using the chemical vapor deposition method (CVD); mixing the raw material mixture containing at least one polymer material, preferably ATH, MDH, EVA, silane 6300, UV stabilizer, titanate, maleic, DOTP, soy, silicone, silicone oil, polyolefin, stearin, paraffin, antioxidant 1076, hydrogen peroxide, preferably using a granule mixer and converting it into granule form, preferably using a twin screw extruder; melting the granules obtained, preferably using a single-screw extruder, adding graphene particles and mixing, then forming and obtaining the protection layer (3); positioning the protection layer (3) to surround the reinforcement layer and obtaining the cable structure (A).

[0038] In a preferred embodiment of the invention, said method of producing the reinforced cable comprises the step of obtaining the reinforcement layer (2) and then coating said insulating layer (4) on said reinforcement layer (2).

[0039] Through the reinforced cable structure and production method developed by the present invention, the conductive material encapsulated graphene material is used in the cable structure to increase the conduction efficiency, prevent energy loss and improve the mechanical and thermal properties of the protection layer (2) without changing the cross-sectional area of the conduction layer (1) of the cable. Thus, a reinforced cable structure (A) that is resistant to physical and chemical external influences, ultraviolet radiation, liquid absorption, local temperature rise and flammability, whose weight value is reduced while maintaining its physical dimensions, which enables the production cost of the cable structure (A) to be reduced and its service life to be increased, and a reinforced cable production method that enables this cable structure to be obtained are obtained.

Claims

CLAIMS1. A reinforced cable structure (A) which comprises at least one conduction layer (1) made of conductive material for the conduction of electricity and / or signals, increases conduction efficiency and prevents energy loss, and improves mechanical, chemical, optical, thermal resistance and heat removal properties, comprising: at least one reinforcing layer (2) which adheres to the surface around the axis of extension of the conduction layer (1) to cover its surface, prevents energy loss on the surface and increases the total conductivity value without changing the cross- sectional area I diameter value of the conduction layer (1), wherein the reinforced layer (2) surrounds the conduction layer (1), and comprises nano-sized graphene particles doped with polyaniline (PANI), coated with at least one conductive capsule material that enables the formation of an interfacial bond between graphene and the conduction layer (1), at least one protection layer (3) which protects the conduction layer (1) and reinforcement layer (2) from physical and chemical external influences, fire and moisture, removes the heat generated in the conduction layer (1) and increases the yield and tensile strength of the cable structure (A), wherein the protection layer (3) is made of polymer material containing nano-sized graphene particles, and surrounds the perimeter of the reinforcement layer (2).

2. A reinforced cable structure (A) according to Claim 1 , wherein the conductive material is copper or aluminum.

3. A reinforced cable structure (A) according to Claim 1 , wherein the conductive capsule material is silver, copper, nickel, gold and / or palladium.

4. A reinforced cable structure (A) according to Claim 1 , wherein the graphene particles in the reinforcement layer (2) are 50-150 nanometers in size.

5. A reinforced cable structure (A) according to Claim 1 , wherein the graphene particles in the mentioned protection layer (3) are 100-300 nanometers in size.

6. A reinforced cable structure (A) according to Claim 1 , wherein the protection layer (3) contains Polyvinyl Chloride (PVC), Thermoplastic Polyurethane (TPU), Halogen Free Flame Retardant (HFFR), Cross Linked Polyethylene (XLPE) and / or Polyethylene (PE).

7. A reinforced cable structure (A) according to Claim 1 , wherein the structure (A) also comprises at least one insulation layer (4) which is positioned between the reinforcement layer (2) and the protection layer (3), made of a polymer material, and protects the position and form of the conduction and reinforcement layers (1 , 2) against impact, bending, crushing, crushing, curling and cutting, and preferably having a thickness value between 0.5 and 1.5 millimeters on an axis perpendicular to the axis of extension of the conduction layer (1), preferably Thermoplastic Polyurethane (TPU) and / or Polyvinyl Chloride (PVC).

8. A method of producing a reinforced cable structure, wherein the reinforced cable structure is obtained according to claim 1 , comprising the steps of: grinding the graphite material by adding ice in it and obtaining graphene particles; sonicating graphene particles in ethanol; obtaining graphene oxide by separating graphene from impurities and treating it in an oxidizing solution containing nitric acid and pure water to introduce hydrophilic groups on its surface; sensitizing the graphene oxide by adding 0.1 M SnCI2 in a water bath to prevent the formation of agglomerations and to separate its surface from foreign substances, and then activating it by adding 0.1 M PdCI2 solution in a water bath to prepare the graphene surface for the coating / encapsulation process; repeatedly adding the activated graphene particles into the coating solution containing conductive capsule material and encapsulating the graphene particles by completely covering them with the conductive capsule material; obtaining the reinforcement layer (2) by mixing the encapsulated graphene particles with polyaniline (PANI) solution and coating the resulting mixture on the conduction layer (1) by using the chemical vapor deposition method (CVD); mixing the raw material mixture containing at least one polymer material and converting it into granule form; melting the obtained granules and adding the graphene particles and mixing them, then forming them and obtaining the protection layer (3);positioning the resulting protection layer (3) to surround the reinforcement layer and obtaining the cable structure (A).

9. A reinforced cable structure production method according to Claim 8, comprising the step of grinding graphite material and ice using a ball mill.

10. A reinforced cable structure production method according to Claim 8, the sonication process comprises the step of applying the sonication process for 80-100 minutes.

11. A reinforced cable structure production method according to Claim 8, the graphene oxide production process comprises the step of treating graphene in oxidizing solution at a temperature of 60-80 °C for 80-100 minutes.

12. A reinforced cable structure production method according to Claim 8, comprising the step of sensitizing the graphene oxide surface in a water bath at 40-60 °C for 20-40 minutes to remove impurities.

13. A reinforced cable structure production method according to Claim 8, wherein the nitric acid is a nitric acid with a mass fraction of 15%.

14. A reinforced cable structure production method according to Claim 8, comprising the step of activating the graphene oxide in a water bath at 50 °C.

15. A reinforced cable structure production method according to Claim 8, comprising the step of increasing the anti-caking efficiency by applying sonication process together with the activation and sensitization processes before the mentioned encapsulation process.

16. A reinforced cable structure production method according to Claim 8, comprising the step of adding the graphene particles activated for the encapsulation process repeatedly for 5 seconds, 1 minute, 3 minutes, 5 minutes, respectively into the coating solution with a pH value of 12 which contains conductive capsule material at 75-95 °C.

17. A reinforced cable structure production method according to Claim 8, wherein the raw material mixture contains ATH, MDH, EVA, silane 6300, UV stabilizer, titanate, maleic, DOTP, soy, silicone, silicone oil, polyolefin, stearin, paraffin, antioxidant 1076, hydrogen peroxide.

18. A reinforced cable structure production method according to Claim 8, comprising the step of mixing the raw material mixture by using a granulating mixer and converting it into granule form by using a twin-screw extruder.

19. A reinforced cable structure production method according to Claim 8, comprising the step of melting the granules by using a single screw extruder.

20. A reinforced cable structure production method according to Claim 8, comprising the step of coating the insulation layer (4) on the reinforcement layer (2) after obtaining the reinforcement layer (2).

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