CN109102959B - 一种高屏蔽同轴电缆制备方法 - Google Patents
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Abstract
本发明提供了一种高屏蔽同轴电缆制备方法,所述同轴电缆由内而外由内导体、绝缘层、外导体、聚酯膜、金属线和护套层组成,所述内导体由多股铜线束绞组成,所述绝缘层由粘结层和发泡层组成,所述外导体由自粘铝箔层、金属丝层和铜箔层组成。本发明产品结构新颖,采用外导体制作与护套挤塑生产一步法完成,比原有外导体编织、绕包、护套挤塑需要三次工序缩短了生产周期,加快交货速度,降低生产成本;外导体采用绕包创新,提高产品耐扭转性能,确保屏蔽衰减性能不偏移;铜箔采用双层结构以及铜层方向朝金属丝层、EVA层方向朝聚酯膜层,确保屏蔽衰减参数高。
Description
技术领域
本发明涉及一种高屏蔽同轴电缆制备方法。
背景技术
随着社会通讯信息的不断发展,电子化产品的高速更新,电磁波相互间距离的不断缩短,相互干扰电磁波现象越来越频繁,且在更新过程中,由于安装时拖拉、弯转、振动都会破坏同轴电缆的信号传输、屏蔽抗干扰效果。从电缆应用的角度考虑,急需开发一种耐扭转、抗弯拉、高屏蔽效果的同轴电缆,解决上述困难。
发明内容
本发明的目的在于解决以上所述的技术问题,提供一种耐扭转、抗弯拉、高屏蔽结构设计的同轴电缆的制备方法。本产品采用外导体制作与护套挤塑生产一步法完成,缩短交货周期,工艺性能参数稳定,生产成本低。
为此,本发明采取以下技术方案:
一种高屏蔽同轴电缆,所述同轴电缆由内而外由内导体、绝缘层、外导体、聚酯膜、金属线和护套层组成,所述内导体由多股铜线束绞组成,所述绝缘层由粘结层和发泡层组成,所述外导体由自粘铝箔层、金属丝层和铜箔层组成。
所述外导体由自粘铝箔层、金属丝层和铜箔层绕包复合而成,所述自粘铝箔层为左向绕包结构,所述金属丝层为右向、左向交叉绕包结构,所述铜箔层为右向绕包结构,所述铜箔层由铜层+PET层+铜层+EVA层复合而成。
所述自粘铝箔层左向绕包在绝缘层上。
所述金属丝层由N股0.16mm镀锡铜丝或裸铜丝组成,金属丝分右向、左向交叉绕包:右向、左向各N/2股,先N/2股金属丝右向绕包在自粘铝箔上,再N/2股金属丝左向绕包在右向金属丝上面。
所述铜箔层右向绕包在金属丝层上。
所述聚酯膜层为左向绕包结构。
所述金属线直径不超过护套层厚度,呈左右对称置于挤塑护套层和聚酯膜间。
一种高屏蔽同轴电缆的方法,包括如下步骤,
一)外导体制作步骤:
1)将由内导体、绝缘层组成的同轴电缆绝缘半成品夹装于主动放线架上,自动调整放线张力;
2)同轴电缆绝缘半成品经过双位导向轮保持走线稳定,进入铝箔绕包架将自粘铝箔为左向绕包在同轴电缆绝缘半成品上,绕包搭盖率15-20%;
3)再进入金属丝缠绕装置,将N股金属丝分右向、左向交叉缠绕在同轴电缆铝箔半成品上,缠绕覆盖率85%以上:
所述金属丝层由N股0.16mm镀锡铜丝或裸铜丝组成,金属丝分右向、左向交叉绕包,右向、左向各N/2股,先N/2股金属丝右向绕包在自粘铝箔上,再N/2股金属丝左向绕包在右向金属丝上面;
4)再进入铜箔绕包架,将铜箔直接右向绕包在同轴电缆金属丝半成品上,绕包搭盖率15-20%;
5)再进入绕膜架,将聚酯膜直接左向绕包在同轴电缆铜箔半成品上,绕包搭盖率20-25%;
二)左右对称金属线成型步骤:
1)2根金属线分别安装在成型架左右对称主动放线架上;
2)所述安装的金属线采用自动张力调节设计,根据金属线重量自动调节张力,确保金属线张力均衡,不因张力不稳定造成产品结构偏移;
3)所述同轴电缆聚酯膜半成品进入成型架,穿过中心管,进入一体化成型模具的中间孔模,并与左右对称的各1根金属线分别同时通过一体化成型模具的左右孔模,形成高屏蔽同轴电缆半成品;
三)所述成型结构的一种高屏蔽同轴电缆半成品快速进入挤塑机的挤塑模具后挤塑PVC护套成型,所述挤塑模具孔模与一体化成型模具孔模成一线,孔径结构设计相同;
四)同轴电缆经过测径仪进行结构检测;
五)同轴电缆经过冷却水槽充分冷却后,经风干机干燥;
六)同轴电缆通过火花仪器进行损伤检测;
七)同轴电缆通过测径仪进行结构检测;
八)同轴电缆通过喷码导向轮进行固定,保持走线稳定;
九)同轴电缆经喷码机进行型号规格等信息喷码标识;
十)同轴电缆通过自动定长装置进行成盘长度的自动测量,便于分盘裁剪识别,保证成盘的有效长度;
十一)最后,将同轴电缆在自动收线机上按照客户需求直接定长成盘。
进一步,步骤一)中,所述的外导体制作设备有铝箔绕包架、金属丝缠绕装置、铜箔绕包架、绕膜架组成;上述设备均采用自动控制系统,通过数据显示,及时调整张力,确保不同绕包包覆均匀一致性;所述铝箔、铜箔、聚酯膜绕包均呈40-50角度,确保搭盖平整、无皱褶;所述金属丝绕管呈360度旋转均匀缠绕在同轴电缆铝箔半成品上;所述铜箔的铜层方向朝金属丝层,EVA层方向朝聚酯膜层。
进一步,步骤二)中,所述成型架由穿线管、2个金属线架、2个导轮、一体化成型模具和自动控制系统组成;所述自动控制系统主要是对2个金属线架的张力自动控制,通过数据显示,及时调整张力,确保金属线张力均衡;所述一体化成型模具有3个孔模,左右孔模孔径相同,穿金属线;中间孔模比左右孔模孔径大,穿同轴电缆半成品线;所述一体化成型模具厚度在25-30mm,确保成型稳定;所述金属线由单根或多股绞合组成。
本发明具有以下优点:1、产品结构新颖,采用外导体制作与护套挤塑生产一步法完成,比原有外导体编织、绕包、护套挤塑需要三次工序缩短了生产周期,加快交货速度,降低生产成本;2、外导体采用绕包创新,提高产品耐扭转性能,确保屏蔽衰减性能不偏移;3、铜箔采用双层结构以及铜层方向朝金属丝层、EVA层方向朝聚酯膜层,确保屏蔽衰减参数高;4、左右对称金属线的设计,提高了受外力的抗弯拉作用;5、对绕包装置自动化创新,有利于产品质量保证,提高产品一次交检合格率。
附图说明
图1为本发明高屏蔽同轴电缆结构图;
其中101-内导体;104-聚酯膜;105--护套层;106-金属线;其中121-粘结层;122-发泡层;131-自粘铝箔层;132-金属丝层;133-铜箔层。
图2本发明制备方法工艺流程及结构示意图;
其中1-主动放线架;2-双位导向轮;3-铝箔绕包架;4-金属丝缠绕装置;5-铜箔绕包架;6-绕膜架;7-成型架;8-挤塑机;9、13-测控仪;10-冷却水槽;11-风干机;12-火花检测仪;14-喷码导向轮;15-喷码机;16-自动定长装置;17-自动收线机。
具体实施方式
实施例一
参照附图1,一种高屏蔽同轴电缆,所述同轴电缆由内而外由内导体101、绝缘层、外导体、聚酯膜104、金属线106和护套层105组成,所述内导体由多股铜线束绞组成,所述绝缘层由粘结层121和发泡层122组成,所述外导体由自粘铝箔层131、金属丝层132和铜箔层133组成。
一种高屏蔽同轴电缆RG11的制备方法,包括如下步骤,
一)外导体制作步骤:
1)将由内导体1.66mm、绝缘层7.11mm组成的RG11绝缘半成品夹装于主动放线架上,自动调整放线张力;
2)RG11绝缘半成品经过双位导向轮保持走线稳定,进入铝箔绕包架,将25×0.12mm自粘铝箔左向绕包在RG11绝缘半成品上,绕包搭盖率18%;
3)再进入金属丝缠绕装置,将96股0.16mm镀锡铜丝分右向、左向交叉缠绕在RG11铝箔半成品上,缠绕覆盖率90%:
将48股0.16mm镀锡铜丝先右向呈45度方向旋转缠绕在自粘铝箔上,缠绕覆盖率90%;再将48股0.16mm镀锡铜丝左向呈45度方向旋转缠绕在在右向镀锡铜丝上面,缠绕覆盖率90%;
4)再进入铜箔绕包架,将28×0.15mm铜箔直接右向呈45度绕包在RG11镀锡铜丝半成品上,绕包搭盖率18%;
5)再进入绕膜架,将29×0.15mm聚酯膜直接左向呈45度绕包在RG11铜箔半成品上,绕包搭盖率22%。
二)左右对称金属线成型步骤:
1)2根直径1.02mm铜包钢分别安装在成型架左右对称主动放线架上;
2)所述安装的铜包钢采用自动张力调节设计,根据铜包钢重量自动调节张力,确保铜包钢张力均衡,不因张力不稳定造成产品结构偏移;
3)所述同轴电缆RG11聚酯膜半成品进入成型架,穿过中心管,进入一体化成型模具的中间孔模,并与左右对称的各1根金属线1.02mm铜包钢分别同时通过一体化成型模具的左右孔模;
三)所述一种高屏蔽RG11成型结构的半成品快速进入挤塑机的挤塑模具后挤塑PVC护套成型,所述挤塑模具孔模与一体化成型模具孔模成一线,孔径结构设计相同;
四)同轴电缆经过测径仪进行结构检测;
五)同轴电缆经过冷却水槽充分冷却后,经风干机干燥;
六)同轴电缆通过火花仪器进行损伤检测;
七)同轴电缆通过测径仪进行结构检测;
八)同轴电缆通过喷码导向轮进行固定,保持走线稳定;
九)同轴电缆经喷码机进行型号规格等信息喷码标识;
十)同轴电缆通过自动定长装置进行成盘长度的自动测量,便于分盘裁剪识别,保证成盘的有效长度;
十一)最后,将同轴电缆在自动收线机上按照客户需求直接定长成盘。
Claims (2)
1.一种高屏蔽同轴电缆制备方法,所述高屏蔽同轴电缆由内而外由内导体、绝缘层、外导体、聚酯膜、金属线和护套层组成,所述内导体由多股铜线束绞组成,所述绝缘层由粘结层和发泡层组成,所述外导体由自粘铝箔层、金属丝层和铜箔层组成;其特征在于:所述高屏蔽同轴电缆的方法包括如下步骤,
一)外导体制作步骤:
1)将由内导体、绝缘层组成的同轴电缆绝缘半成品夹装于主动放线架上,自动调整放线张力;
2)同轴电缆绝缘半成品经过双位导向轮保持走线稳定,进入铝箔绕包架将自粘铝箔为左向绕包在同轴电缆绝缘半成品上,绕包搭盖率15-20%;
3)再进入金属丝缠绕装置,将N股金属丝分右向、左向交叉缠绕在同轴电缆铝箔半成品上,缠绕覆盖率85%以上:
所述金属丝层由N股0.16mm镀锡铜丝或裸铜丝组成,金属丝分右向、左向交叉绕包,右向、左向各N/2股,先N/2股金属丝右向绕包在自粘铝箔上,再N/2股金属丝左向绕包在右向金属丝上面;
4)再进入铜箔绕包架,将铜箔直接右向绕包在同轴电缆金属丝半成品上,绕包搭盖率15-20%;
5)再进入绕膜架,将聚酯膜直接左向绕包在同轴电缆铜箔半成品上,绕包搭盖率20-25%;
二)左右对称金属线成型步骤:
1)2根金属线分别安装在成型架左右对称主动放线架上;
2)所述安装的金属线采用自动张力调节设计,根据金属线重量自动调节张力,确保金属线张力均衡,不因张力不稳定造成产品结构偏移;
3)所述同轴电缆聚酯膜半成品进入成型架,穿过中心管,进入一体化成型模具的中间孔模,并与左右对称的各1根金属线分别同时通过一体化成型模具的左右孔模,形成高屏蔽同轴电缆半成品;
其中,所述成型架由穿线管、2个金属线架、2个导轮、一体化成型模具和自动控制系统组成,所述自动控制系统主要是对2个金属线架的张力自动控制,通过数据显示,及时调整张力,确保金属线张力均衡;所述一体化成型模具有3个孔模,左右孔模孔径相同,穿金属线;中间孔模比左右孔模孔径大,穿同轴电缆半成品线;所述一体化成型模具厚度在25-30mm,确保成型稳定;所述金属线由单根或多股绞合组成;
三)高屏蔽同轴电缆半成品快速进入挤塑机的挤塑模具后挤塑PVC护套成型,所述挤塑模具孔模与一体化成型模具孔模成一线,孔径结构设计相同;
四)同轴电缆经过测径仪进行结构检测;
五)同轴电缆经过冷却水槽充分冷却后,并经风干机干燥;
六)同轴电缆通过火花仪器进行损伤检测;
七)同轴电缆通过测径仪进行结构检测;
八)同轴电缆通过喷码导向轮进行固定,保持走线稳定;
九)同轴电缆经喷码机进行型号规格等信息喷码标识;
十)同轴电缆通过自动定长装置进行成盘长度的自动测量后,便于分盘裁剪识别,保证成盘的有效长度;
十一)最后,将同轴电缆在自动收线机上按照客户需求直接定长成盘。
2.如权利要求1所述的高屏蔽同轴电缆制备方法,其特征在于:步骤一)中,所述的外导体制作设备有铝箔绕包架、金属丝缠绕装置、铜箔绕包架、绕膜架组成;
上述设备均采用自动控制系统,通过数据显示,及时调整张力,确保不同绕包包覆均匀一致性;
所述铝箔、铜箔、聚酯膜绕包均呈40-50角度,确保搭盖平整、无皱褶;
金属丝绕管呈360度旋转均匀缠绕在同轴电缆铝箔半成品上;
所述铜箔的铜层方向朝金属丝层,EVA层方向朝聚酯膜层。
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