EP2184744B1 - Elektrischer Draht mit niedriger dielektrizitatskonstante PTFE Hülle, Herstellungs- Verfahren und -Werkzeug - Google Patents

Elektrischer Draht mit niedriger dielektrizitatskonstante PTFE Hülle, Herstellungs- Verfahren und -Werkzeug Download PDF

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Publication number
EP2184744B1
EP2184744B1 EP09174913.5A EP09174913A EP2184744B1 EP 2184744 B1 EP2184744 B1 EP 2184744B1 EP 09174913 A EP09174913 A EP 09174913A EP 2184744 B1 EP2184744 B1 EP 2184744B1
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Prior art keywords
conductor
section
extrudate
covering
spacer
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English (en)
French (fr)
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EP2184744A1 (de
Inventor
Sophie Perez
Chor Yeung
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Axon Cable SA
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Axon Cable SA
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H01B13/141—Insulating conductors or cables by extrusion of two or more insulating layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
    • H01B3/443—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from vinylhalogenides or other halogenoethylenic compounds
    • H01B3/445—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from vinylhalogenides or other halogenoethylenic compounds from vinylfluorides or other fluoroethylenic compounds
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H01B7/0233—Cables with a predominant gas dielectric

Definitions

  • the invention relates to an electrical wire comprising at least one single-stranded or stranded electrical conductor, in a sheath based on PTFE (polytetrafluoroethylene), and a method and a manufacturing tool that make it possible to manufacture it. It also relates to the coaxial cable that can be formed around such an electric wire.
  • PTFE polytetrafluoroethylene
  • conductor here denotes a bare conductor, but may optionally include a conductive outer plating, for example a silver plating or other.
  • the conductor can be single-stranded or stranded.
  • PTFE-based sheath is meant here a sheath predominantly composed of PTFE, which may further comprise other fillers such as dyes, etc.
  • the electrical wire targeted by the invention is a wire intended for the transmission of a signal, in particular at high or very high frequency.
  • Insulation plays a very important role in the electrical performance of an electrical cable, and particularly in the field of high frequency signal transmission.
  • the speed of propagation of electromagnetic waves depends on the dielectric constant ⁇ of the insulator, and is inversely proportional to the square root of the latter.
  • the attenuation of the transmitted signals is a function involving the frequency and the dielectric constant of the insulating medium. Materials which have the lowest possible dielectric constant for insulation are thus sought, so as to produce low attenuation cables.
  • Fluorinated polymers, PTFE in particular are often chosen for this application because they have dielectric constants ⁇ very low, from 2.0 to 2.1.
  • a first solution is to choose an insulating material further comprising the porous material. This brings a considerable improvement in performance because the dielectric constant of the air is only 1; the presence of air in the insulation thus makes it possible to lower the dielectric constant.
  • cables insulated with expanded PTFE may have a dielectric constant between 1.7 and 1.3 depending on the porosity of the PTFE.
  • the patent WO 2005/066979 to EI Dupont de Nemours thus describes a method of manufacturing electrical wires comprising one or more conductors, protected by a PTFE sheath, the sheath comprising continuous longitudinal cells.
  • the cells of the electric wire obtained are separated from the conductor by a layer of PTFE.
  • This electrical wire 10 comprises a central conductor 12, and a sheath 14.
  • the conductor 12 is a single-strand copper conductor of circular section.
  • the sheath 14 is a hollow sheath of substantially cylindrical shape (on a substantially straight section of wire), inside which are formed four continuous longitudinal cells 16.
  • the cells 16 are separated in pairs by separating partitions or spacers 18
  • the conductor is housed in a sheath 20 which is directly in contact with its outer surface, on which the radially inner ends of the struts 18 rest.
  • the presence of the sheath 20 causes the cells 16 to be at a distance from the conductor 12. which limits their ability to reduce the dielectric constant of the electric wire.
  • a first object of the invention is therefore to propose an electrical wire comprising at least one conductor held by at least one spacer in a PTFE-based sheath, the sheath and said at least one spacer further forming at least one substantially longitudinal cell. continuous, said at least one cell being at least partially defined by the conductor, the electric wire having high performance, that is to say a dielectric constant ⁇ very low, and having one or more cells having a high resistance to 'crushing.
  • the PTFE fibers of said at least one spacer are mainly directed in a substantially radial direction.
  • the dielectric constant of this electric wire may be less than 1.7.
  • the spacer or spacers ensure the relative positioning of the conductor in the sheath. Because the PTFE fibers of this or these spacers are predominantly (and in fact in general, essentially) directed in the radial direction, the spacers or spacers have a high compressive strength and therefore the cells themselves. have a very good resistance to compression. It follows that the electric wire has a high durability, with a risk of crushing cells and therefore loss of dielectric properties very low.
  • the direction 'radial' designates the direction in which are formed the spacer or spacers, that is to say, usually the radial direction.
  • this direction may possibly not be radial; in this case, the radial direction designates the direction in which the spacers extend, according to the section of the electric wire.
  • a single cell is formed. There is therefore only one spacer for the maintenance of the driver.
  • the angular position of the cell and the spacer vary along the wire. Note that it may also be useful to provide this same arrangement (angular position of the variable cell along the wire) in the case where the wire is formed with several cells.
  • the electrical wire according to the invention can in particular be formed with two to four cells, or more; two to four drivers, or more.
  • the sheath is kept at a distance from the conductor by said at least one spacer, the latter comprising a substantially radial junction portion, and a holding portion enlarged in contact with the conductor.
  • the term 'enlarged' indicates here that the holding portion is wider than the joining portion.
  • the enlarged part ensures a better support of the conductor by the spacer (compared to a spacer which does not include an enlarged part), without significantly penalizing neither the dielectric constant nor the weight of the cable, the junction part of the remaining spacer relatively thin.
  • the invention also relates to a coaxial cable comprising a central conductor, an insulating intermediate sheath based on PTFE, an outer conductor, an outer protective sheath and whose central conductor considered with the intermediate sheath is an electric wire as defined above according to the invention.
  • a second object of the invention is to define a method for manufacturing an electrical wire comprising at least one conductor in a PTFE-based sheath, the sheath and said at least one spacer forming at least one continuous longitudinal cell, which is passed a PTFE-based extrudate in an extrusion passage around said at least one conductor so as to form the sheath, and which allows the formation of a cell delimited at least partially by the driver, and thus the obtaining a very low dielectric constant electric wire E.
  • the process thus comprises two successive steps.
  • the shaping takes place for the most part, during which the sheath generally takes on its final shape (in particular, with the shrinkage).
  • this formatting requires machine settings known for the implementation of the PTFE, in particular to obtain fibrillation of PTFE.
  • the sheath is formed, at least a portion of the sheath being formed at a distance from the conductor, leaving a space between a free surface of the conductor, which remains exposed, and the sheath portion intended to become the outer wall of the cell.
  • This sheath portion is formed to its definitive shape, which means that it is formed with the shape that it will retain in the manufactured electrical wire.
  • the cells will be formed, forming connecting struts between the aforementioned sheath portion and the conductor.
  • These spacers are formed because during the progression of the extrudate in the tooling, from the expansion section, the guide which separated the outer portion of the sheath, the driver, is replaced by one or more profiles.
  • This profile (It may be several profiles) extends downstream in the extension that a portion of the guide, and at least one expansion channel is formed between the walls of the profile (s) ).
  • the extrudate As the extrudate progresses in the extrusion passage, as soon as the extrudate reaches the expansion section, it fills this expansion channel, and thus forms one or more struts connecting the outer sheath to the conductor. .
  • the material of the spacers therefore comes from the material of the outer sheath, which flows radially towards the conductor or conductors to form the spacers. These spacers form the walls of the cell or alveoli.
  • the formation of the spacers is not accompanied by the covering of the free surfaces of the conductor by the extrudate, for reasons indicated below. Also, the free surface (s) remain free, thus making it possible to obtain an electrical wire of particularly low dielectric constant.
  • the originality of the method thus lies in the fact that although the sheath is essentially shaped during the first stage (upstream of the expansion section), the extrudate retains a residual capacity of expansion, advantageously used in the process to form from the expansion section or spacers connecting the sheath to the conductor and constituting the radial or lateral walls of the cells. These spacers ensure the correct positioning of the conductor relative to the sheath.
  • the formation of the spacers only after the forming of the sheath prevents the appearance of PTFE on the free surface of the conductor, and keeps it naked within the cell.
  • the viscosity of the PTFE extrudate is very high, and the extrudate only flows under a very strong pressure. If necessary, depending on the viscosity of the PTFE, it may be useful to reduce this viscosity by increasing the proportion of lubricant in the extrudate (that is to say in the mixture to be extruded at the time of preparation of the latter). this). Increasing the proportion of lubricant modulates the creep of the extrudate occurring during extrusion. According to the invention, the extrudate flows from and downstream of the expansion section, releasing the residual stresses that are in it and whose relaxation is critical.
  • the reduction ratio immediately downstream of the expansion section is smaller than the reduction ratio of a so-called 'maximum reduction' section located at or upstream of the expansion section in the extrusion passage.
  • the reduction ratio is equal to the ratio between the area of a section of the compression chamber at the upstream portion of the tooling and the area of the section considered of the die.
  • the pressure in the extrusion passage is less at the (or immediately downstream of) the expansion section than the level of the maximum reduction section. Because of this, the filling of the expansion channel (s) with PTFE is measured, and the invasion of the volume of the cells by the extrudate is avoided.
  • the reduction ratio immediately downstream of the expansion section is 10% or more lower than that of the maximum reduction section.
  • the expansion section is located at a distance downstream of an extrusion orifice of the tool located downstream of an extrusion chamber of decreasing section.
  • the extrudate shaped at the the vicinity of the extrusion orifice thus has a period of time allowing it to stabilize during its progression between the extrusion orifice and the expansion section.
  • the contact between the extrudate and the conductor takes place substantially at the level of the expansion section, at which point the respective axial speeds of the extrudate and the conductor are substantially equal. In this way, the shear forces applying to the interface between the extrudate and the conductor are minimized, which avoids the risk of breakage of the conductor during manufacture.
  • a third objective of the invention is to define a tool for manufacturing an electrical wire comprising at least one conductor in a PTFE-based sheath, the sheath and said at least one spacer forming at least one continuous longitudinal cell delimited at least partially by the conductor, and which allows the manufacture of an electric wire of very low dielectric constant.
  • the inner diameter of the minimum diameter of the guide - or the extension thereof - in fact substantially corresponds to the diameter that must have the driver, to allow effective guidance of the driver without unnecessary play.
  • the profile extends substantially to this surface, during the manufacture of the electric wire, the surface internal profile is in the vicinity of the driver. Thanks to this, the risk of invasion by the PTFE of the space between the conductor and the profile remains limited: PTFE having a high viscosity, when this space is reduced, the PTFE does not penetrate, allowing to preserve the free surface or surfaces of the driver.
  • the machine in which the tooling is mounted must include means for using the extrudate, which allow the formation and fibrillation of the PTFE contained in the extrudate, when the extrudate is shaped in the passage extrusion.
  • the tooling immediately downstream of the expansion section a passage surface of the extrudate greater than that of a so-called 'maximum reduction' section of the tool located further upstream.
  • the passage area of the extrudate immediately downstream of the expansion section may be 10% greater than that of the maximum reduction section.
  • the expansion section is located downstream of an extrusion orifice of the tool located downstream of an extrusion chamber of decreasing section.
  • the tooling comprises at least one adjustable portion, for axially varying the position of the expansion section in the tooling.
  • the viscosity of the extrudate can vary depending on the operating conditions and the raw material used. These variations lead to more or less filling of the expansion channels.
  • the position of the expansion channels it is possible to trigger the filling of these channels more or less long after forming the sheath, and thus to control the importance of filling these channels.
  • said at least one profile is a solid section.
  • a section is easy to achieve, and the process requires neither vacuum, nor air injection for the formation of cells.
  • the electrical wire 22 comprises a central conductor 24, and a sheath 26 based on PTFE.
  • the central conductor 24 is constituted by a copper core 23, having a thin silver plating 27.
  • the silver plating 27 has been shown with an exaggerated thickness on the figure 2 .
  • the sheath 26 is an outer sheath, substantially cylindrical and tubular.
  • the sheath 26 has a generally tubular shape; the spacers 30 make it possible to center the conductor 24 inside the sheath 26.
  • the struts 30 extend from the inner wall of the sheath 26 to the conductor 24 in a radial direction.
  • the spacers 30 comprise a substantially radial junction portion 32, which forms a relatively thin or thin partition wall between two adjacent cells 28, and an enlarged portion 34 formed at the point of contact between the spacer 30 and the conductor 24.
  • Each of the cells 28 is partially delimited by the conductor 24 at a free surface 25, which is not covered with PTFE and remains 'naked' inside the cell 28.
  • the electric wire 22 is shown during manufacture.
  • the cavities 28 are partly occupied by profiled tooling portions 29 (or sections 29, shown hatched) serving to form the cavities 28.
  • the cells 28 occupy the volume of these sections 29, as well as the volumes voids 31 which each extend between two spacers 30, the conductor 24 and a profile 29.
  • the formation of the spacers 30 is illustrated in particular by the detail left in the upper left on the figure 2 .
  • the sheath 26 is formed in a first step of manufacturing the electrical wire 22 in a first step of manufacturing the electrical wire 22, the sheath 26 is formed.
  • a portion of the extrudate constituting the sheath 26 flows radially inwards, along the arrows B, in the space provided between the sections 29, thus forming the spacers 30 between the walls of the profiles 29. flow is stopped by the driver 24; however, in contact with the latter at the end of the struts 30 the extrudate flow divides, and partially fills the annular space between the conductor 24 and the profiles 29, thereby forming one or more enlarged portions 34 to the end of the spacers 30.
  • the manufacturing tool is arranged and adjusted to limit this expansion. In particular, the high viscosity of the extrudate can be taken into account if necessary to reduce the extrudate entry into the space available between the conductor 24 and the profiles 29.
  • Each of the spacers 30 has a joining portion 32, and an enlarged portion 34.
  • the radial axis of the spacer 30 is represented by the dashed line A.
  • the width 38 of the enlarged portion 34 is greater than the width 36 of the joining portion 32 of the spacer 30, these two widths being measured perpendicularly to the radial axis A.
  • the portion 34 may be more or less wide depending on the setting of the manufacturing tool, thus allowing a arbitration between an electrical wire having a very low dielectric constant and wherein the spacers 30 provide less maintenance of the conductor 24 (because their enlarged portion 34 is little or not widened), or the opposite.
  • the section of the electric wire as represented on the figure 2 is invariant along the axis of it.
  • figure 2 shows the direction in which the PTFE fibers 33 are formed in the sheath and spacers, during the manufacture of the electrical wire.
  • the PTFE fibers in the spacers are mainly directed in a substantially radial direction, since this is the direction in which the spacers 30 extend to connect the outer sheath to the central conductor 24.
  • This orientation of the fibers 33 PTFE is due to the fact that during the manufacture of the wire, after the formation of the outer sheath of the wire, the formation of the spacers is done using the material of the outer sheath, the material of the outer sheath fluent in direction of the central electrical wire 24 so as to form the spacers 30.
  • This direction of extension of PTFE fibers 33 in the spacers gives them excellent crush resistance.
  • the figure 3 represents another electrical wire according to the invention, comprising two conductors 40, each conductor being surrounded by four cells 42.
  • An outer sheath 44 based on PTFE is formed around the conductors and their cells.
  • each of the cells 42 is partially delimited by one of the conductors 40.
  • the cells have been formed so as to minimize the dielectric constant of the wire.
  • the spacers 46 formed between adjacent cells, do not have an enlarged portion in contact with the conductor.
  • the cells 42 In a section perpendicular to the longitudinal axis of the wire (for example the section of the figure 3 ), the cells 42 have a shape of angular sector, relatively large center angle ⁇ , for example 80 degrees; the spacers 46 also have a substantially angular sector shape but their central angle ⁇ is reduced to about 10 to 20 degrees.
  • This electrical wire 50 comprises a single-strand electric conductor 52 disposed inside a sheath 54 made of PTFE-based material.
  • the sheath 54 is tubular. Inside the latter, the free space 56 between the central conductor 52 and the sheath 54 is only occupied by a helicoidal spacer 58 which connects the outer surface of the conductor 52 to the inner surface of the sheath 54.
  • E dielectric constant
  • the figure 5 has a coaxial cable incorporating an electrical wire according to the invention.
  • This coaxial cable 60 integrates, successively, a central electrical conductor 62, a tubular sheath 64 made of PTFE material, separated from the central conductor 62 by four cavities 66, a conductive layer 68 and finally an outer sheath 70. Thanks to the presence longitudinal cells 66, each being partially delimited by the conductor 62, the dielectric constant E of the coaxial cable is very small.
  • the figure 6 presents a production tooling 100 adapted for the implementation of the method according to the invention. It also has a portion of electrical wire 150 made by this tool.
  • the tool 100 mainly comprises a die 102 and a guide 104.
  • the die 102 has an internal passage 106 within which the sheathing of PTFE-based material takes place.
  • This passage 106 has a general shape of revolution around an extrusion axis B.
  • the axis B is a vertical axis and the extrusion takes place in the downward direction.
  • the guide 104 also has a general shape of revolution and is arranged coaxially with the axis B of the die 102, inside the internal passage 106 thereof.
  • the internal passage 106 of the die has three main parts, which correspond to the three main phases of the extrusion:
  • the internal passage 106 comprises a cylindrical chamber 108 or upstream compression chamber. During manufacture, this cylindrical chamber is filled with lubricated material ready for extrusion, forming the extrudate.
  • the extrudate is pushed down by a slide 110 sliding inside the chamber 108 around the guide 104. Under the effect of the pressure exerted by the slide or piston 110, the extrudate is pushed down to the interior of the cylindrical chamber 108, then in a convergent conical 112.
  • the inner passage 106 has a third portion which is the extrusion passage 114.
  • the extrusion passage is of substantially cylindrical and extends over a certain height below the outlet orifice 116 of the convergent 112.
  • the guide 104 also has an outer shape in three parts. Its cylindrical upper part 118 is adapted to allow the piston 110 to slide around it; this upper portion 118 is extended downwards by a conical portion 120. The cone of this portion 120 is adapted relative to the convergent 112 to allow a progressive pressure increase of the extrudate and an increase in the reduction ratio, as and when as the extrudate is lowered into the internal passage 106 of the die.
  • the guide 104 is finally extended by a downstream cylindrical portion 122. In the downward extension of this downstream cylindrical portion 122, four sections 124 extend, which serve to form the cells in the electrical wire manufactured by the tool. 100.
  • the four sections 124 each have the same shape; they extend inside the cylindrical envelope of the downstream cylindrical portion 122 of the guide 104, each occupying an angular sector within this volume. Between each pair of adjacent profiles 124 is formed an expansion channel 126.
  • the expansion channels 126 thus form four radial slits 0.8 mm wide, separating the profiles 124 at the end of the guide 104.
  • the guide 104 serves to guide a conductor 128, which is the central conductor of the electrical wire 150 manufactured with the tooling 100.
  • the four sections 124 extend radially inwardly substantially to the contact of the central conductor 128.
  • the inner diameter of the guide 104 is 2.8 mm, while the conductor 128 has an outer diameter of 2.27 mm . So, a light game is provided between the guide 104 and the conductor 128, which clearance is sufficient to allow the substantially frictionless circulation of the conductor in the tooling, but is sufficiently small to prevent any extrudate rising within the guide 104 in the passage provided for the driver 128.
  • the extrudate consists of a mixture consisting essentially of PTFE and lubricant.
  • a solvent based on aliphatic hydrocarbons may be used, for example in a proportion of 10 to 35%, and preferably 15 to 25%.
  • a conductor 128 is set up inside the guide 104, and the cylindrical chamber 108 is filled with extrudate ready for extrusion.
  • the amount of lubricant present in the extrudate is adjusted to allow sufficient creep thereof during extrusion.
  • the piston 110 descends gradually and, at the same time, the conductor 128 is driven downwards.
  • the extrudate is compressed in the cylindrical chamber 108, then inside the convergent 112 and engulfs via the outlet orifice 116 of the convergent 112 in the extrusion passage 114.
  • the extrusion passage 114 comprises a first upstream portion 101 for forming the sheath of the electrical wire, this upstream portion extending from the outlet of the convergent 116 to the downstream section of the guide said expansion section 130.
  • the extrudate During its passage in this first upstream part of the extrusion passage 114, the extrudate is subjected to fibrillation which makes it possible to form the sheath 160 of the electrical wire 150 manufactured, between the outer wall of the guide 104, of diameter 5 mm, and the inner wall of the die 102, with a diameter of 6 mm. It is therefore for the tooling a sheath formation part, in which the shape of the extrudate is stabilized in enjoy the game.
  • the extrudate is introduced into this first upstream portion, at the outlet orifice 116 of the internal passage 106, through a passage section which has the shape of the section of the outer sheath of the formed wire.
  • the sheath material expands and fills the four expansion channels 126. By filling these channels, the material of the sheath forms the spacers 158 joining and holding between the central conductor 128 and the sheath 160.
  • a second portion 103 of the extrusion passage, or strut forming part, extends from the expansion section 130 to the downstream section of the profiles 124.
  • the cell separation struts are formed.
  • the extrudate constituting the spacers is shaped and stabilized.
  • the formation of the spacers is by creep of the material of the outer sheath, taking advantage of the residual expansion capabilities that the PTFE constituting the sheath at this stage of the extrusion.
  • the tool is arranged in such a way that the material of the spacers can come only from the outer sheath.
  • upstream of each spacer 30 is the downstream cylindrical portion 122 of the guide 104. The latter makes it possible to form the inner surface of the outer sheath inside the first upstream portion 101, but thereby prevents the forming the spacers 30 in this part 101.
  • a downstream cylindrical portion 105 of the die 102 allows stabilization and ultimate maintenance of the sheath 160 before the output of the wire 150 to the outside of the tool 100.
  • the electrical wire 150 thus shaped then requires sintering to stabilize the structure of the sheath 160 and spacers 158 by thermal coalescence.
  • the cell manufacturing process can be better understood in relation to the Figures 7 and 8 .
  • the process of forming the electrical wire jacket is a continuous process that takes place during the progression of the extrudate along the B axis in the production tool 100. As it progresses, the extrudate crosses certain points on the axis B at which the shape of the tool 100 varies.
  • the extrudate progresses firstly in the compression chamber, to an X 0 abscissa on the B axis from which the guide 104 is of minimum diameter and is extended by a cylindrical portion 122. Further downstream, to the X1 abscissa, the extrudate reached, at the downstream end of the compression chamber, the orifice 116 or convergent outlet orifice 112 of the die 102. Downstream of this orifice 116, the extrudate progresses in a cylindrical portion of the die 102, around the guide 104.
  • the guide 104 terminates at the expansion section 130 at an abscissa X 2 .
  • the guide 104 is extended downstream of this expansion section 130 by the profiles 124, which serve to form the four cells of the electrical wire.
  • the profiles 124 extend to a section X 3 inside the die 102, and the die 102 extends downstream of these profiles to an abscissa X 4 (downstream of X 3 ).
  • the figure 8 presents the evolution of the reduction ratio in the manufacturing tool as the extrudate advances in it. From the injection of the extrudate upstream of the compression chamber, in a first step, the reduction ratio increases when the extrudate is compressed inside the convergent 112. From the abscissa X 0 , from which the guide adopts a cylindrical shape 122, the reduction ratio increases even faster to reach a maximum value R 1 from X 1 . This high value of the reduction ratio R 1 is chosen so as to allow fibrillation of the extrudate in the first portion 101 of the extrusion passage 114. Thus, this first portion 101 of the extrusion passage allows the forming of the sheath 160 of the electrical wire 150.
  • the extrudate passage space is increased due to the opening of the expansion passages 126 between the profiles 124.
  • the extrudate fills the expansion channels 126 and forms the separating walls between the cells, namely the spacers 158 for holding the sheath 160 of the electrical wire 150.
  • the reduction ratio decreases to a second value R2 less than R1.
  • the extrudate has taken its final form.
  • the length of this second portion 103 of the extrusion passage is chosen to be sufficient to allow the stabilization of the extrudate, which takes in this part 103 its substantially definitive form.
  • the profiles 124 terminate at abscissa X 3 , leaving the cells 158 filling with air.
  • This filling takes place inside the third portion 105 of the extrusion passage, in which the guide of the sheath by the die 102 promotes the maintenance of the shape of the sheath and prevents the collapse thereof on the alveoli.
  • the cable has an outside diameter of 5.3 mm.
  • the degree of vacuum in the dielectric is estimated at 28%, and the dielectric constant ⁇ is measured equal to 1.47, which confirms the efficiency of the structure chosen for the production of electric cables of low dielectric constant.
  • An important parameter for the setting of the tool and the development of the manufactured electrical wire is the position of the expansion section 130 (abscissa X2) in the tool. Indeed, the further the expansion section 130 is upstream, near the outlet port 116 of the convergent 112, the less the PTFE of the extrudate is stabilized in the sheath. Therefore, the closer the expansion section 130 is to this outlet port 116, the further the extrudate can enter the expansion channels 126 and, therefore, the spacers 158 will have an enlarged portion in contact with each other. of the driver.
  • the tooling 100 comprises an adjustable part comprising the cylindrical portion 122 of the guide associated with the profiles 124, this part being able to be displaced axially vertically in the direction of extrusion (arrow F) by an actuator 140, as a function of the greater or lesser importance that the widened part of the struts 158 of the wire 150 has to have.
  • the adjustable part By raising the adjustable part upwards (in the direction opposite to the arrow F, in figure 6 ), the length of the portion 101 of the extrusion passage 114 is reduced, thus the spacers 158 are allowed to be formed shortly after the formation of the sheath 160.
  • the sheath then being unstabilized, an increased amount of of PTFE moves radially between the profiles 124 to form the spacers 158, and accordingly these have a larger enlarged portion.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Processes Specially Adapted For Manufacturing Cables (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Claims (13)

  1. Stromkabel (22, 50), das wenigstens einen Leiter (24, 40, 52) aufweist, der von mindestens einem Abstandshalter (30, 46, 58) in einem Mantel (26, 44, 54) auf PTFE-Basis gehalten wird, wobei der Mantel und der mindestens eine Abstandshalter ferner mindestens eine ununterbrochene Längszelle (28, 42, 56) bilden, wobei die mindestens eine Zelle mindestens teilweise von dem Leiter abgegrenzt ist,
    wobei das Stromkabel dadurch gekennzeichnet ist, dass die PTFE-Fasern des mindestens einen Abstandshalters in einem Querschnitt senkrecht zu der Achse des Kabels gesehen überwiegend in eine im Wesentlichen radiale Richtung gerichtet sind.
  2. Stromkabel nach Anspruch 1, dessen Mantel von dem mindestens einen Abstandshalter (30), der einen im Wesentlichen radialen Verbindungsteil (32) und einen Halteteil (34), der an der Berührung des Leiters verbreitert ist, aufweist, von dem Leiter beabstandet gehalten wird.
  3. Koaxialkabel (60), das einen zentralen Leiter (62), einen isolierenden Zwischenmantel (64) auf PTFE-Basis, einen äußeren Leiter (68) und einen äußeren Schutzmantel (70) aufweist, dadurch gekennzeichnet, dass der zentrale Leiter (62) mit dem Zwischenmantel (64) betrachtet ein Stromkabel nach Anspruch 1 und 2 ist.
  4. Verfahren zum Herstellen eines Stromkabels, das mindestens einen Leiter (24, 40) aufweist, der von wenigstens einem Abstandshalter in einem Mantel (26, 44, 54) auf PTFE-Basis gehalten wird, wobei der Mantel und der mindestens eine Abstandshalter (30, 46, 58) mindestens eine im Wesentlichen ununterbrochene Längszelle (28, 42, 56) bilden,
    wobei man bei dem Verfahren ein Extrudat auf PTFE-Basis in einer Extrusionpassage (114) um den mindestens einen Leiter durchgehen lässt, um den Mantel zu bilden,
    dadurch gekennzeichnet, dass
    - auf einem ersten Teil (101) der Extrusionpassage, stromaufwärts eines Ausdehnungsquerschnitts (130) mindestens ein Teil des Mantels im Wesentlichen mit seiner endgültigen Form von dem Leiter durch eine Führung beabstandet ausgebildet ist, die das Extrudat in Entfernung von einer freien Oberfläche des Leiters (25) hält,
    - stromabwärts des Ausdehnungsquerschnitts die mindestens eine Zelle auf der freien Oberfläche (25) durch mindestens ein Profil (124), das sich in der Verlängerung eines Teils der Führung (104) erstreckt, ausgebildet ist, wobei mindestens ein Abstandshalter (158) zum Halten des Mantelteils auf dem Leiter durch Füllen mindestens eines Ausdehnungskanals (126), der sich zwischen den Wänden des mindestens einen Profils öffnet, ausgebildet ist.
  5. Herstellungsverfahren nach Anspruch 4, bei dem das Verringerungsverhältnis (R) unmittelbar stromabwärts des Ausdehnungsquerschnitts (130) kleiner ist als das Verringerungsverhältnis eines sogenannten Querschnitts (X1) "mit maximaler Verringerung", der auf dem Niveau oder stromaufwärts des Ausdehnungsquerschnitts (130) in der Extrusionspassage (114) liegt.
  6. Herstellungsverfahren nach Anspruch 5, bei dem das Verringerungsverhältnis (R) unmittelbar stromabwärts des Ausdehnungsquerschnitts (130) im Vergleich zu dem des Querschnitts mit maximaler Verringerung kleiner ist als 10 % oder mehr.
  7. Herstellungsverfahren nach einem der Ansprüche 4 bis 6, bei dem der Ausdehnungsquerschnitt (130) in einer Entfernung stromabwärts einer Extrusionsöffnung (116) des Werkzeugs (100), das sich stromabwärts einer Extrusionskammer mit abnehmendem Querschnitt (112) befindet, liegt.
  8. Herstellungsverfahren nach einem der Ansprüche 4 bis 7, bei dem der Kontakt zwischen dem Extrudat und dem Leiter im Wesentlichen auf dem Niveau des Ausdehnungsquerschnitts (130) auftritt, dem Niveau, bei dem die jeweiligen axialen Geschwindigkeiten des Extrudats und des Leiters (128) im Wesentlichen gleich sind.
  9. Werkzeug (100) zum Herstellen eines Stromleiters (150), der mindestens einen Leiter (128) aufweist, der von mindestens einem Abstandshalter (30, 46, 58) in einem Mantel (160) auf PTFE-Basis gehalten wird, wobei der Mantel und der mindestens eine Abstandshalter mindestens eine im Wesentlichen ununterbrochene Längszelle (28, 42, 56) bilden, die mindestens teilweise von dem Leiter abgegrenzt ist, wobei Werkzeug dadurch gekennzeichnet ist, dass es umfasst:
    stromaufwärts eines Ausdehnungsquerschnitts (130) eine Führung (104), die geeignet ist, um einen äußeren Mantelteil im Wesentlichen mit seiner endgültigen Form um den Leiter auszubilden, wobei diese Führung vorgesehen ist, um das Extrudat von mindestens einer freien Oberfläche (25) des Leiters, die man nicht mit Extrudat abdecken will, beabstandet zu halten,
    stromabwärts des Ausdehnungsquerschnitts, in der Verlängerung eines ersten Teils der Führung, mindestens ein Profil (124), wobei dieses Profil geeignet ist, die wenigstens eine Zelle auf der freien Oberfläche zu bilden, wobei Wände des wenigstens einen Profils wenigstens einen Ausdehnungskanal (126) definieren, dessen Füllen das Ausbilden mindestens eines Abstandshalters zum Halten des äußeren Mantelteils auf dem Leiter erlaubt,
    wobei sich das mindestens eine Profil radial im Wesentlichen bis zu der inneren Oberfläche des Mindestdurchmessers der Führung erstreckt, um das Eindringen von Extrudat auf der freien Oberfläche (25) des Leiters (128) zu verhindern.
  10. Herstellungswerkzeug (100) nach Anspruch 9, das unmittelbar stromabwärts des Ausdehnungsquerschnitts eine Durchgangsoberfläche des Extrudat aufweist, die größer ist als diejenige eines so genannten Querschnitts mit maximaler Verringerung des Werkzeugs, der weiter stromaufwärts liegt.
  11. Herstellungswerkzeug nach Anspruch 9 oder 10, dessen Ausdehnungsquerschnitt (130) stromabwärts einer Extrusionsöffnung (116) des Werkzeugs, das sich stromabwärts einer Extrusionskammer mit abnehmendem Querschnitt (112) befindet, liegt.
  12. Herstellungswerkzeug nach einem der Ansprüche 9 bis 11, das mindestens einen einstellbaren Teil aufweist, der es erlaubt, die Position des Ausdehnungsquerschnitts in dem Werkzeug axial variieren zu lassen.
  13. Herstellungswerkzeug nach einem der Ansprüche 9 bis 12, von dem mindestens ein Profil ein massives Profil ist.
EP09174913.5A 2008-11-06 2009-11-03 Elektrischer Draht mit niedriger dielektrizitatskonstante PTFE Hülle, Herstellungs- Verfahren und -Werkzeug Active EP2184744B1 (de)

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FR0857537A FR2938111B1 (fr) 2008-11-06 2008-11-06 Fil electrique a gaine de ptfe a faible constante dielectrique, et ses procede et outil de fabrication

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EP2184744A1 (de) 2010-05-12
FR2938111B1 (fr) 2012-08-03
US20100108355A1 (en) 2010-05-06
US8618417B2 (en) 2013-12-31

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