CN121011399A - Tensile-resistant self-sealing marine composite cable and its manufacturing process - Google Patents

Abstract

This invention discloses a tensile-resistant, self-sealing marine composite cable, comprising a main core, a ground core, an inner sheath, an armor layer, and an outer sheath. Key features include: it also includes optical fiber units and a central filler. The optical fiber units employ embedded distributed optical fiber sensors. Three main cores, two ground cores, and the optical fiber units are stranded into a cable core, with a central filler at the center, which is a semi-conductive rubber strip. The inner sheath is made of graphene-modified polyurethane extruded over the cable core. The armor layer is woven from a mixture of stainless steel wire and aramid fiber, forming a spiral armor structure with double-layer reverse winding at a 45° helix angle. The outer sheath is made of graphene-modified polyurethane extruded over the armor layer.

Description

Tensile self-sealing marine composite cable and production process thereof

Technical Field

The invention relates to the technical field of power cables, in particular to a tensile self-sealing marine composite cable and a production process thereof.

Background

The marine cable is a cable special for electric power, illumination, control, communication, microcomputer and other systems of various ships, offshore oil platforms and water buildings. Based on the requirements of durability, fire resistance, water resistance and signal stability of the marine cable in severe environments, the marine cable has higher requirements than the cable used on ordinary land. The Chinese patent document CN212032686U discloses a control cable for resisting high Wen Jianchuan, wherein the cable core comprises a plurality of wires and basalt fibers, the wires are uniformly distributed in the basalt fibers, the innermost layer of the wires is a wire core formed by twisting a plurality of conductor wires, a polyimide layer is arranged outside the wire core, a glass fiber cloth layer is arranged outside the polyimide layer, an aluminum strip braiding layer is arranged outside the glass fiber cloth layer, an polysulfonamide fiber cloth layer is arranged outside the cable core, a steel strip braiding layer is arranged outside the polysulfonamide fiber cloth layer, a graphite fiber layer is arranged outside the steel strip braiding layer, a conductive paint coating is arranged outside the graphite fiber layer, and a polyether-ether-ketone layer is arranged outside the conductive paint coating. The control cable for the ship, which utilizes the characteristics of different materials and is scientifically combined, has excellent high-temperature resistance and excellent anti-interference capability, and ensures the stable operation of all parts of the ship. Due to the requirements of the use environment, the marine cable also needs to have good waterproof performance. The Chinese patent document CN 205247931U discloses a multi-core split-phase lead-coated optical fiber composite submarine cable, the cable comprises a cable core, the cable core comprises three power cables and a communication optical cable, the cable core is coated with a reinforced binding tape, an inner liner, a metal armor layer and an outer coating in sequence, the power cable comprises three power cores, the power cores are coated with a water blocking conductor, a conductor shielding layer, an insulating shielding layer, a semi-conductive water blocking buffer layer, a split-phase metal radial water blocking layer, a semi-conductive polyethylene sheath layer, a non-moisture absorption filling layer and a reinforced binding tape in sequence from the inner liner to the outer coating, the inner liner and the outer coating are all made of anti-corrosion asphalt polypropylene fibers, the communication optical cable mainly comprises a six-core stainless steel pipe optical unit, an armor metal layer and a polyethylene outer jacket, and the armor metal layer is a phosphorized steel wire layer, and the cable has the advantages of water resistance, good insulativity, long service life and high reliability, and can effectively reduce construction work load and engineering investment cost. The cable for submarine laying needs to have good waterproof performance and good tensile performance in the face of a laying mode.

Disclosure of Invention

The invention aims to provide a tensile self-sealing marine composite cable with a simple structure, good waterproof performance and good tensile performance and a production process thereof.

The invention discloses a tensile self-sealing marine composite cable which comprises a main wire core, a ground wire core, an inner sheath, an armor layer and an outer sheath. The structure is characterized by also comprising an optical fiber unit and a center filling. The optical fiber unit adopts an embedded distributed optical fiber sensor. The cable core is formed by twisting 3 main wire cores, 2 ground wire cores and optical fiber units, the center of the cable core is provided with a center filling, and the center filling adopts a semi-conductive rubber strip. The inner sheath is extruded outside the cable core by adopting graphene modified polyurethane. The armor layer is formed by mixed braiding of stainless steel wires and aramid wires, and is formed by double-layer reverse winding at a helix angle of 45 degrees. The outer sheath is extruded outside the armor layer by adopting graphene modified polyurethane.

Further, in order to improve water resistance, the main wire core is sequentially provided with a conductor, a conductor shielding layer, an insulating layer and an insulating shielding layer from inside to outside along the respective radial directions.

The conductor is formed by stranding a plurality of 5 types of tinned copper wires, the wire is stranded, and water-blocking powder is filled in the conductor. The conductor shielding layer, the insulating layer and the insulating shielding layer are wrapped outside the conductor by three layers of coextrusion. The conductor shielding layer adopts crosslinked polyethylene, the insulating layer adopts fluoroplastic, and the insulating shielding layer adopts thermoplastic polyurethane.

Further, in order to improve water blocking performance, the main wire core is further provided with a wrapping layer, the wrapping layer is wrapped outside the conductor by adopting a water blocking belt, and the wrapping covering rate is 15% -30%.

Further, in order to improve reliability, the ground wire cores are sequentially provided with a ground wire core conductor and a semiconductive layer from inside to outside along respective radial directions thereof. The ground wire core conductor is formed by stranding a plurality of 5 tinned copper wires into first bunched wires and then stranded wires. The semiconductive layer is extruded outside the ground wire core conductor by a semiconductive shielding material extruder.

The production process of the tensile self-sealing marine composite cable comprises the following steps:

1) Twisting a plurality of 5 tinned copper wires to form first stranded wires and then stranded wires, and placing the stranded wires after stranded wires on a pay-off disc of a cage strander for layered stranding;

2) The conductor shielding layer is made of crosslinked polyethylene material, the insulating layer is made of fluoroplastic material, and the insulating shielding layer is made of thermoplastic polyurethane material;

3) The ground wire core conductor of the ground wire core is formed by stranding a plurality of 5 types of tinned copper wires to form first bunched wires and then stranded wires;

4) Twisting 3 main wire cores, 2 ground wire cores and an optical fiber unit into a cable core, and directly dragging the semiconductive rubber strip from the center to form center filling during twisting;

5) Extruding graphene modified polyurethane outside the cable core to form an inner sheath;

6) The method comprises the steps that a stainless steel wire and aramid fiber mixed braiding layer is adopted, a spiral armor structure is formed by double-layer reverse winding of a 45-degree spiral angle, the 45-degree spiral angle is ensured by a braiding guide wheel during braiding, the braiding guide wheel is provided with V-shaped grooves, the included angle of each V-shaped groove is 90 degrees, 45-degree inclined planes are formed on two sides of each V-shaped groove, and therefore stainless steel wires or aramid fiber wires positioned on a lower spindle of a braiding machine can be led to leave the inclined planes in a layered mode at a fixed angle of 45 degrees for braiding;

7) And forming an outer sheath outside the armor layer by adopting graphene modified polyurethane extrusion.

Further, in order to ensure the coating effect, the step 1 further comprises the following steps:

and wrapping the stranded conductor with a layer of water-blocking tape to form a wrapping layer, wrapping the wrapping layer with a covering rate of 15-30%, and wrapping the conductor shielding layer, the insulating layer and the insulating shielding layer outside the wrapping layer by adopting three-layer co-extrusion.

The tensile self-sealing marine composite cable has the advantages that (1) the tensile self-sealing marine composite cable is simple in structure, the conductor is filled with water-blocking powder, the water-blocking power expands 300% when meeting water, the waterproof performance is good, and the tensile performance can be improved by adopting spiral armor. (2) The inner sheath and the outer sheath of the tensile self-sealing marine composite cable are made of graphene modified polyurethane materials, so that the barrier performance to water vapor, oxygen, oil and other chemical media is improved. The inner conductor and the insulating layer are better protected from being corroded by ambient moisture, the growth of water trees is slowed down (which is particularly important for the power cable), and the insulating reliability is improved. Enhancing chemical corrosion resistance and prolonging the service life in severe environments such as greasy dirt, chemical industry and the like. (3) The tensile self-sealing marine composite cable is provided with the optical fiber unit, the optical fiber unit is embedded into the distributed optical fiber sensor (the interval is 0.5 m), the temperature strain is monitored in real time, the fault point (the precision is +/-15 cm) is positioned through an algorithm, and the early warning response time is less than 3 seconds. (4) The tensile self-sealing marine composite cable has simple production process and can be accurately controlled. The traditional spiral armor is characterized in that the angle of the driving gear and the driven gear is determined and can be influenced by the wire diameter and the vehicle speed, and the angle is difficult to accurately control. The 45-degree angle is the optimal angle, and if the angle is too large and the wire is broken, the woven skylight can be very large and is difficult to repair. The angle is too small, and the outer sheath procedure is easy to shrink. Through testing, the tensile strength is improved by 40%, and the bending life reaches more than 10000 times (ISO 6722 standard).

Drawings

Fig. 1 is a schematic structural view of a tensile self-sealing marine composite cable according to the present invention.

Fig. 2 is a schematic structural view of a braided guide wheel in the production process of the tensile self-sealing marine composite cable of the invention.

The reference numerals in the drawings are:

a main wire core 1, a conductor 11, a conductor shielding layer 12, an insulating layer 13, an insulating shielding layer 14,

The ground wire core 2, the ground wire core conductor 21, the semiconductive layer 22,

The optical fiber unit 3,

The center-fill 4 is provided with a plurality of holes,

The inner sheath (5) is provided with a pair of inner sheath,

The layer of armour 6 is formed,

The outer sheath 7 is provided with a pair of outer sleeves,

Braiding guide wheels 10 and V-shaped grooves 10-1.

Detailed Description

In order that the invention may be more readily understood, a more particular description of the invention will be rendered by reference to specific embodiments that are illustrated in the appended drawings. The description of the azimuth of the present invention is performed according to the azimuth shown in fig. 1, that is, the up-down-left-right direction shown in fig. 1 is the up-down-left-right direction of the description, the direction facing in fig. 1 is the front, and the direction facing away from fig. 1 is the rear. It should be understood that the terms "upper," "lower," "inner," "outer," and the like indicate orientations or positional relationships based on the positional relationships described in the drawings, and are merely used to facilitate describing the invention or simplify the description, and do not indicate a particular orientation that must be assumed.

Example 1

Referring to fig. 1, the tensile self-sealing marine composite cable of the invention comprises a main wire core 1, a ground wire core 2, an optical fiber unit 3, a center filling 4, an inner sheath 5, an armor layer 6 and an outer sheath 7.

The number of the main wire cores 1 is 3, and the structures of the 3 main wire cores 1 are the same. The 3 main wire cores 1 are respectively provided with a conductor 11, a wrapping layer 15, a conductor shielding layer 12, an insulating layer 13 and an insulating shielding layer 14 from inside to outside along the radial direction of each main wire core.

The conductor 11 is formed by stranding a plurality of 5 types of tinned copper wires, the wires are bundled firstly, then the wires are stranded, and the conductor 11 is filled with water-blocking powder. The wrapping layer 15 is wrapped outside the conductor 11 by adopting a water blocking tape, and the wrapping covering rate is 15% -30%. The conductor shielding layer 12, the insulating layer 13 and the insulating shielding layer 14 are wrapped outside the wrapping layer 15 by three layers of coextrusion. The conductor shielding layer 12 is made of crosslinked polyethylene (XLPO), the insulating layer 13 is made of fluoroplastic, and the insulating shielding layer 14 is made of Thermoplastic Polyurethane (TPU).

The number of the ground wire cores 2 is 2, and the structures of the 2 ground wire cores 2 are the same. The 2 ground wire cores 2 are respectively provided with a ground wire core conductor 21 and a semiconductive layer 22 in turn from inside to outside along the respective radial directions. The ground wire core conductor 21 is formed by twisting a plurality of 5 types of tinned copper wires into first bunched wires and then stranded wires. The semiconductive layer 22 is extruded over the ground wire core conductor 21 using a semiconductive shield extruder.

The optical fiber unit 3 employs an embedded distributed optical fiber sensor (pitch 0.5 m). The optical fiber unit 3 can monitor the temperature strain in real time, locate the fault point (precision + -15 cm) through an algorithm, and early warning response time is less than 3 seconds.

The cable core is formed by twisting 3 main wire cores 1,2 ground wire cores 2 and an optical fiber unit 3. The center of the cable core is provided with a center filling 4, the center filling 4 is formed by extruding a semiconductive material to form a semiconductive rubber strip, and the semiconductive rubber strip has a supporting function on one hand and can prevent partial discharge and insulation breakdown on the other hand. The inner sheath 5 is extruded outside the cable core by adopting graphene modified polyurethane.

The armor layer 6 is formed by mixed braiding of stainless steel wires and aramid wires, and is formed by double-layer reverse winding at a helix angle of 45 degrees.

The outer sheath 7 is extruded outside the armor layer 6 by adopting graphene modified polyurethane.

Referring to fig. 2, the production process of the tensile self-sealing marine composite cable comprises the following steps:

1) And the stranded wires after the wire bundling are coated with water-blocking powder before the stranded wires, the water-blocking powder is placed in a box body, and the stranded wires are stuck with the water-blocking powder after passing through the box body.

According to a further optimization scheme, the stranded conductor 11 is wrapped with a layer of water blocking tape to form a wrapping layer 15, and the wrapping covering rate is 15-30%, so that the water blocking powder coating rate is improved.

2) The conductor shielding layer 12, the insulating layer 13 and the insulating shielding layer 14 are wrapped outside the wrapping layer 15 by three layers of co-extrusion, so that the main wire core 1 is manufactured. The conductor shielding layer 12 is made of crosslinked polyethylene (XLPO) material, the insulating layer 13 is made of fluoroplastic material, and the insulating shielding layer 14 is made of Thermoplastic Polyurethane (TPU) material.

3) The ground wire core conductor 21 of the ground wire core 2 is formed by stranding a plurality of 5 types of tinned copper wires, and is stranded firstly and then stranded. The semiconductive layer 22 is extruded over the ground wire core conductor 21 using a semiconductive shield extruder.

4) 3 Main wire cores 1, 2 ground wire cores 2 and an optical fiber unit 3 are twisted into a cable core, and the center is directly dragged by the semi-conductive rubber strip to form a center filling 4 during twisting.

5) And extruding graphene modified polyurethane to form an inner sheath 5 outside the cable core.

6) The mixed braiding layers of the stainless steel wires and the aramid wires are adopted, a spiral armor structure is formed by double-layer reverse winding of the spiral angles of 45 degrees, the spiral angles of 45 degrees are ensured by the braiding guide wheel 10 during braiding, the braiding guide wheel 10 is provided with V-shaped grooves 10-1, the included angle of the V-shaped grooves 10-1 is 90 degrees, accordingly 45-degree inclined planes are formed on two sides, the braiding guide wheel 10 is a ceramic guide wheel, and the stainless steel wires or the aramid wires positioned on a lower spindle of a braiding machine can be led to leave the inclined planes in a layered mode at a fixed angle of 45 degrees for braiding.

Through testing, the tensile strength is improved by 40%, and the bending life reaches more than 10000 times (ISO 6722 standard).

7) And the outer sheath 7 is formed by extruding graphene modified polyurethane outside the armor layer 6.

While the foregoing is directed to embodiments of the present invention, other and further details of the invention may be had by the present invention, it should be understood that the foregoing description is merely illustrative of the present invention and that no limitations are intended to the scope of the invention, except insofar as modifications, equivalents, improvements or modifications are within the spirit and principles of the invention.

Claims (6)

1. A tensile self-sealing marine composite cable comprises a main wire core (1), a ground wire core (2), an inner sheath (5), an armor layer (6) and an outer sheath (7), and is characterized by further comprising an optical fiber unit (3) and a center filler (4), wherein the optical fiber unit (3) is an embedded distributed optical fiber sensor, the 3 main wire core (1), the 2 ground wire cores (2) and the optical fiber unit (3) are stranded into a cable core, the center filler (4) is arranged in the center of the cable core, the center filler (4) is a semiconductive rubber strip, the inner sheath (5) is formed by mixing and braiding graphene modified polyurethane outside the cable core, the armor layer (6) is formed by mixing and braiding stainless steel wires and aramid wires, a spiral armor structure is formed by reversely winding the armor layer (6) in a 45-degree double-layer spiral angle mode, and the outer sheath (7) is formed by extruding graphene modified polyurethane outside the armor layer (6).

2. The tensile self-sealing marine composite cable according to claim 1, wherein the main wire core (1) is sequentially provided with a conductor (11), a conductor shielding layer (12), an insulating layer (13) and an insulating shielding layer (14) from inside to outside along the respective radial directions;

The conductor (11) is formed by stranding a plurality of 5 types of tinned copper wires to form first bundle wires and then stranded wires, water-blocking powder is filled in the conductor (11), the conductor shielding layer (12), the insulating layer (13) and the insulating shielding layer (14) are wrapped outside the conductor (11) by three layers of co-extrusion, the conductor shielding layer (12) is made of crosslinked polyethylene, the insulating layer (13) is made of fluoroplastic, and the insulating shielding layer (14) is made of thermoplastic polyurethane.

3. The tensile self-sealing marine composite cable according to claim 2, wherein the main wire core (1) is further provided with a wrapping layer (15), the wrapping layer (15) is wrapped outside the conductor (11) by adopting a water blocking tape, and the wrapping covering rate is 15% -30%.

4. The tensile self-sealing marine composite cable according to claim 1, wherein the ground wire core (2) is sequentially provided with a ground wire core conductor (21) and a semiconductive layer (22) from inside to outside along the respective radial directions, the ground wire core conductor (21) is formed by twisting a plurality of 5 types of tinned copper wires into a first bundle wire and then twisted, and the semiconductive layer (22) is extruded outside the ground wire core conductor (21) by a semiconductive shielding material extruder.

5. The production process of the tensile self-sealing marine composite cable comprises the following steps:

1) Twisting a plurality of 5 tinned copper wires to form first stranded wires and then stranded wires, and placing the stranded wires after stranded wires on a pay-off disc of a cage strander for layered stranding;

2) The conductor shielding layer (12), the insulating layer (13) and the insulating shielding layer (14) are extruded outside the conductor (11) in a three-layer co-extrusion mode to form a main wire core (1), wherein the conductor shielding layer (12) is made of a crosslinked polyethylene material, the insulating layer (13) is made of a fluoroplastic material, and the insulating shielding layer (14) is made of a thermoplastic polyurethane material;

3) The ground wire core conductor (21) of the ground wire core (2) is formed by twisting a plurality of 5 types of tinned copper wires into a first wire bundle and then twisted;

4) Twisting 3 main wire cores (1), 2 ground wire cores (2) and an optical fiber unit (3) into a cable core, wherein the center is directly pulled by a semiconducting rubber strip to form a center filling (4) during twisting;

5) Extruding graphene modified polyurethane outside the cable core to form an inner sheath (5);

6) The method comprises the steps that a mixed knitting layer of stainless steel wires and aramid wires is adopted, double layers of spiral armor structures are formed by reversely winding the mixed knitting layer at a spiral angle of 45 degrees, the spiral angle of 45 degrees is ensured by a knitting guide wheel (10) during knitting, the knitting guide wheel (10) is provided with V-shaped grooves (10-1), the included angle of the V-shaped grooves (10-1) is 90 degrees, 45-degree inclined planes are formed on two sides, and therefore the stainless steel wires or the aramid wires positioned on a lower spindle of a knitting machine can be guided in a layered mode to leave the inclined planes at a fixed angle of 45 degrees for knitting;

7) And an outer sheath (7) is formed outside the armor layer (6) by adopting graphene modified polyurethane extrusion.

6. The process for producing a self-sealing marine composite cable according to claim 5, wherein the step 1 further comprises the steps of:

The twisted conductor (11) is wrapped with a layer of water-blocking tape to form a wrapping layer (15), the wrapping covering rate is 15-30%, the water-blocking powder coating rate is improved, and the three layers of co-extrusion wrapping conductor shielding layer (12), insulating layer (13) and insulating shielding layer (14) are arranged outside the wrapping layer (15).