CN109524154A - 一种加强导体聚氨酯护套电焊机电缆及其制造方法 - Google Patents
一种加强导体聚氨酯护套电焊机电缆及其制造方法 Download PDFInfo
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Abstract
本发明提供一种加强导体聚氨酯护套电焊机电缆及其制造方法,包括由内至外依次设置的带中心加强纤维绳的铜线复绞软导体、高强度尼龙包带层、乙丙橡胶绝缘层以及聚氨酯护套层,所述中心加强纤维绳采用芳纶丝编织或超高分子量聚乙烯纤维编织,所述铜线复绞软导体外重叠绕包高强度尼龙带形成高强度尼龙包带层。具有高抗张强度、超高耐磨性和抗撕裂性、耐低温、抗霉菌、耐各种油脂及酸碱化学品、耐辐照、阻燃、短时过载能力强、寿命长等优点,性能优于传统电焊机电缆,特别适合使用于各种恶劣环境中,是特殊环境下传统电焊机电缆的替代产品。
Description
技术领域
本发明涉及电缆领域,具体是指一种加强导体聚氨酯护套电焊机电缆及其制造方法。
背景技术
电焊机电缆也叫焊把线,是适用于电焊机二次侧接线及连接电焊钳的专用电缆,现执行标准GB/T 5013.6-2008。电焊机电缆在低电压(最高电压为200V) 大电流的条件下工作,电缆长期允许工作温度不超过65℃。电缆频繁地移动,扭绕和施放要求柔软弯曲性能好。在施放中易受到尖锐钢铁构件的刮、擦,故要求电缆抗撕、耐磨等机械性能好。使用环境条件复杂如日晒、水沸、接触泥水、机油、酸碱液体等要求有一定的耐气候性和耐油、耐溶剂性。电缆结构为单线芯采用多股软铜导线复绞制成,导电线芯外面采用耐热聚酯薄膜绝缘带绕包最外层用橡皮制成的绝缘兼护套做为保护层。本发明是区别于传统电焊机电缆,采用加强导体聚氨酯护套,具有高抗张强度、超高耐磨性和抗撕裂性、耐低温、抗霉菌、耐各种油脂及酸碱化学品、耐辐照、阻燃、短时过载能力强、寿命长等优点,性能优于传统电焊机电缆,特别适合使用于各种恶劣环境中,是特殊环境下传统电焊机电缆的替代产品。
发明内容
本发明的在于针对现有电焊机电缆产品的不足,提供一种加强导体聚氨酯护套电焊机电缆及其制造方法,高性能、寿命长、适合各种恶劣环境。
本发明的技术方案:
一种加强导体聚氨酯护套电焊机电缆,包括由内至外依次设置的带中心加强纤维绳的铜线复绞软导体、高强度尼龙包带层、乙丙橡胶绝缘层以及聚氨酯护套层,所述中心加强纤维绳采用芳纶丝编织或超高分子量聚乙烯纤维编织,所述铜线复绞软导体外重叠绕包高强度尼龙带形成高强度尼龙包带层。
所述乙丙橡胶绝缘层采用IE4型乙丙橡胶。
所述聚氨酯护套层使用国产聚醚型环保阻燃热塑性聚氨酯弹性体。
一种加强导体聚氨酯护套电焊机电缆的制造方法,包括以下具体步骤:
束丝导体使用带有退扭功能的笼式绞线机绞制软铜导体,绞制时加强纤维绳位于导体中央位置,绞制最外层节距比不大于12倍,控制各放线盘张力基本一致,加强导体直流电阻符合GB/T 5013.6-2008要求;
绝缘符合GB/T 5013.1-2008中规定的IE4型乙丙橡胶绝缘,通过连硫生产线由挤出机挤出绝缘后通过连续硫化管道进行连续硫化;
聚氨酯护套挤出,普通挤塑机采用挤管式或半挤管式模具挤出,成品电缆通过冷却成型通过收线机收在收线盘上。
所述绝缘的挤包线速度20米/min,连硫管道气压不低于1.2Mpa,连续硫化挤出机各部分控制温度:挤出机各段40℃-90℃,机头模口90℃-110℃,挤包后线芯进行在线15kV工频电压试验。
所述聚氨酯护套在90型挤塑机上完成,采用挤管式模具,挤出速度9米/min,挤出机各部分控制温度:挤出机各段80℃-150℃,机头模口150℃-160℃,挤出标称护套厚度1.3mm,挤包后直径控制范围10.2-10.5mm,成品电缆通过冷却成型通过收线机收在收线盘上,成品电缆进行1kV浸水电压试验。
与现有技术相比,本发明的有益效果是:
1、导体中心设有加强纤维绳,纤维绳采用芳纶丝编织或超高分子量聚乙烯纤维编织,具有高拉断力、耐冲击、柔软性高、耐弯曲、耐高低温、阻燃,在同等重量的条件下,至少为钢丝的5倍强度、E级玻璃纤维的2.5倍强度。例如 2毫米左右纤维绳可承受300公斤拉断力,加强纤维的加入增强了电焊机电缆的抗拉强度,导体外重叠绕包高强度尼龙包带进一步增加强度,电缆使用寿命成倍增长。
2、绝缘采用IE4型乙丙橡胶,保证高绝缘性能,短时过载能力极强。
3、护套使用国产聚醚型环保阻燃热塑性聚氨酯弹性体,具有超高耐磨性、高抗张强度及撕裂强度、耐油脂及酸碱化学品、优异的耐低温性能、抗霉菌、阻燃环保、柔软弯曲性好、耐辐照,成品护套强度可达40MPa,耐低温可达-60℃,电焊机电缆可在各种恶劣环境中使用,使用寿命长。
附图说明
图1为本发明加强导体聚氨酯护套电焊机电缆横截面结构示意图;
图2为本发明生产流程示意图。
图中标号分别表示,1-带中心加强纤维绳铜软导体,2-高强度尼龙包带层, 3-乙丙橡胶绝缘层,4-聚氨酯护套层。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
本发明提供一种技术方案:
本发明加强导体聚氨酯护套电焊机电缆结构为:1、带中心加强纤维绳铜软导体2、高强度尼龙包带层3、乙丙橡胶绝缘层4、聚氨酯护套层。
参照图2,其制造方法工艺加工过程:①、束丝导体使用带有退扭功能的笼式绞线机绞制软铜导体,绞制时加强纤维绳位于导体中央位置,绞制最外层节距比不大于12倍,控制各放线盘张力基本一致,加强导体直流电阻符合GB/T 5013.6-2008要求;②、绝缘符合GB/T 5013.1-2008中规定的IE4型乙丙橡胶绝缘,通过连硫生产线由挤出机挤出绝缘后通过连续硫化管道进行连续硫化,绝缘厚度见表1;③、聚氨酯护套挤出,普通挤塑机采用挤管式或半挤管式模具挤出,挤出护套厚度见表1,成品电缆通过冷却成型通过收线机收在收线盘上。
表1:加强导体聚氨酯护套电焊机电缆技术参数
实施例1:16mm 2加强导体聚氨酯护套电焊机电缆
导体采用0.2mm铜丝,使用束丝机先进行导体束丝,束丝结构93根0.2mm 左向绞合,束丝节距比不大于25倍;每个93根铜线组成的束丝导体做为一股再进行导体复绞,复绞采用1+6右向绞合,在带有退扭功能的笼式绞线机上完成,1根直径1.8mm加强纤维绳位于绞线中央,***6根93/0.2mm束绞导体,控制各放线盘张力基本一致,加强导体直流电阻符合GB/T 5013.6-2008要求,导体20℃直流电阻不大于1.19Ω/km,导体外单层重叠绕包高强度尼龙带,包带后直径6.2-6.5mm。
在90型连硫生产线上挤包白色乙丙绝缘胶,通过连硫生产线由挤出机挤出绝缘后通过连续硫化管道进行连续硫化,乙丙绝缘符合GB/T 5013.1-2008中规定的IE4型乙丙橡胶,标称绝缘厚度0.7mm,挤包后直径7.6-7.9mm,挤包线速度20米/min,连硫管道气压不低于1.2Mpa,连硫挤出机各部分控制温度:挤出机各段40℃-90℃,机头模口90℃-110℃,挤包后线芯进行在线15kV工频电压试验。
挤包红色聚醚型环保阻燃热塑性聚氨酯弹性体护套,在90型挤塑机上完成,采用挤管式模具,挤出速度9米/min,挤出机各部分控制温度:挤出机各段80℃ -150℃,机头模口150℃-160℃,挤出标称护套厚度1.3mm,挤包后直径控制范围10.2-10.5mm,成品电缆通过冷却成型通过收线机收在收线盘上,成品电缆进行1kV浸水电压试验。
本发明加强导体聚氨酯护套电焊机电缆与现有电焊机电缆性能比较:
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。
Claims (6)
1.一种加强导体聚氨酯护套电焊机电缆,其特征在于:包括由内至外依次设置的带中心加强纤维绳的铜线复绞软导体(1)、高强度尼龙包带层(2)、乙丙橡胶绝缘层(3)以及聚氨酯护套层(4),所述中心加强纤维绳采用芳纶丝编织或超高分子量聚乙烯纤维编织,所述铜线复绞软导体(1)外重叠绕包高强度尼龙带形成高强度尼龙包带层(2)。
2.根据权利要求1所述的加强导体聚氨酯护套电焊机电缆,其特征在于:所述乙丙橡胶绝缘层(3)采用IE4型乙丙橡胶。
3.根据权利要求1所述的加强导体聚氨酯护套电焊机电缆,其特征在于:所述聚氨酯护套层(4)使用国产聚醚型环保阻燃热塑性聚氨酯弹性体。
4.一种加强导体聚氨酯护套电焊机电缆的制造方法,其特征在于:包括以下具体步骤:
束丝导体使用带有退扭功能的笼式绞线机绞制软铜导体,绞制时加强纤维绳位于导体中央位置,绞制最外层节距比不大于12倍,控制各放线盘张力基本一致,加强导体直流电阻符合GB/T 5013.6-2008要求;
绝缘符合GB/T 5013.1-2008中规定的IE4型乙丙橡胶绝缘,通过连硫生产线由挤出机挤出绝缘后通过连续硫化管道进行连续硫化;
聚氨酯护套挤出,普通挤塑机采用挤管式或半挤管式模具挤出,成品电缆通过冷却成型通过收线机收在收线盘上。
5.根据权利要求4所述的一种加强导体聚氨酯护套电焊机电缆的制造方法,其特征在于:所述绝缘的挤包线速度20米/min,连硫管道气压不低于1.2Mpa,连续硫化挤出机各部分控制温度:挤出机各段40℃-90℃,机头模口90℃-110℃,挤包后线芯进行在线15kV工频电压试验。
6.根据权利要求4所述的一种加强导体聚氨酯护套电焊机电缆的制造方法,其特征在于:所述聚氨酯护套在90型挤塑机上完成,采用挤管式模具,挤出速度9米/min,挤出机各部分控制温度:挤出机各段80℃-150℃,机头模口150℃-160℃,挤出标称护套厚度1.3mm,挤包后直径控制范围10.2-10.5mm,成品电缆通过冷却成型通过收线机收在收线盘上,成品电缆进行1kV浸水电压试验。
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