CN109461521A - A kind of fluid insulation cable making method and cable - Google Patents

A kind of fluid insulation cable making method and cable Download PDF

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Publication number
CN109461521A
CN109461521A CN201811567044.7A CN201811567044A CN109461521A CN 109461521 A CN109461521 A CN 109461521A CN 201811567044 A CN201811567044 A CN 201811567044A CN 109461521 A CN109461521 A CN 109461521A
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China
Prior art keywords
core
cable
outside
area
wrapped
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CN109461521B (en
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张广柱
张东杰
王雪松
祝军
李斌
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Jiangsu Shangshang Cable Group Co Ltd
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Jiangsu Shangshang Cable Group Co Ltd
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    • 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
    • H01B7/0045—Cable-harnesses
    • 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
    • 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
    • H01B13/02—Stranding-up
    • 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
    • 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
    • H01B13/148—Selection of the insulating material therefor
    • 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
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/221—Sheathing; Armouring; Screening; Applying other protective layers filling-up interstices
    • 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
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/24—Sheathing; Armouring; Screening; Applying other protective layers by extrusion
    • 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
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
    • 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
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
    • H01B13/2606—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by braiding
    • 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
    • H01B7/0009—Details relating to the conductive cores
    • 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
    • H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/182—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring comprising synthetic filaments
    • H01B7/183—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring comprising synthetic filaments forming part of an outer sheath
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/1865—Sheaths comprising braided non-metallic layers
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/187—Sheaths comprising extruded non-metallic layers
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/1875—Multi-layer sheaths
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/22—Metal wires or tapes, e.g. made of steel
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/22—Metal wires or tapes, e.g. made of steel
    • H01B7/228—Metal braid
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • H01B7/2806—Protection against damage caused by corrosion
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • H01B7/282—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
    • H01B7/2825—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable using a water impermeable sheath
    • 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
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/14—Extreme weather resilient electric power supply systems, e.g. strengthening power lines or underground power cables

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulated Conductors (AREA)

Abstract

A kind of manufacturing method of fluid insulation cable, step include: first to manufacture conductor strand and copper foil conductor；The manufacture of each function cable；After function cable and gasket for packing are twisted into big cable core jointly, further around packet nonwoven fabric belts, thermoplastic elastomer sheath material is extruded outside nonwoven fabric belts and constitutes inner sheath, metal mesh shaped structure is wrapped up outside inner sheath, then wrap up separation layer in metal mesh shaped structure baby；4) outer elastomer sheathing material is extruded outside nonwoven fabric belts.Cable made from the above method is that big cable core is made of more root functionality cable twists, and big cable core gap is filled by gasket for packing；Wrapped nonwoven fabric belts, which are overlapped, outside big cable core constitutes nonwoven layer；Oversheath is wrapped up outside nonwoven layer；Inner sheath is wrapped up outside non-woven fabrics outside big cable core, the reticular structure that wire is constituted is wrapped up outside inner sheath, has separation layer outside reticular structure, oversheath is wrapped up outside separation layer.Function cable includes active force core, wire core, accessory power supply core, the first signal core group, second signal core group.

Description

A kind of fluid insulation cable making method and cable
Technical field
The technical program belongs to field of cable technology, specifically a kind of fluid insulation cable making method and cable.
Background technique
That there is specific energies is low for the common lithium ion power storage battery of new-energy automobile at present, and the primary continual mileage that charges is short The problem of.Therefore, in the case where current driving force battery cannot provide more continual mileages, if the charging for being able to achieve battery is fast Speedization solves the short deadly defect of electric car continual mileage from another angle.Charge the rapid demand for becoming development. Three-element catalytic technology, gradually maturation, the specific energy of power accumulator of graphene technology are constantly being promoted simultaneously, and this requires not While realizing quick charge, meet the high-power charging of battery, realizes the powerful transmitting of charging.
Either hybrid vehicle, pure electric automobile or fuel cell car all be unable to do without high-voltage electric system.It is pure Electric car and plug-in hybrid-power automobile take more than the high voltage and several hundred amperes of high currents of 300V.The promotion meeting of voltage The requirement on electric performance of charging components, higher cost are improved, the estimated highest of following voltage is promoted to 1000V.The promotion of electric current Essential approach as high-power charging.Current electric current maximum may achieve 250A, and the cable of charging has used 95mm2Electricity Cable, to guarantee the safety of actual use.When electric current continues to increase to 400A, the cross-sectional area of conductor of traditional charging cable needs Reach 185 squares of mm or 240 square of mm, cable substance is big, outer diameter is big, inconvenient for use.If electric current rises to 500A again, fill Cross-sectional area of conductor, the outer diameter of electrical cables need to continue to increase, bring cable weight, not flexible, purchase cost is high, inconvenient, raw Produce the disadvantages of processing is difficult to control.
The electric current of high-power charging is larger (250A is promoted to 400A or more), for the fever phenomenon for solving cable, harness Diameter therewith thicker (50mm or more), the operability of charging reduces, and the economy of scheme reduces.So having to design newly Scheme solves the heating problem of high current, transmits biggish electric current with lesser cable.
Summary of the invention
In order to solve the above-mentioned problems in the prior art, the technical program proposes a kind of hollow cable and its manufacturer Method, specifically:
A kind of fluid insulation cable, big cable core is made of more root functionality cable twists, and big cable core gap is filled by gasket for packing； Wrapped nonwoven fabric belts, which are overlapped, outside big cable core constitutes nonwoven layer；Oversheath is wrapped up outside nonwoven layer, constitutes cable；
The radial section of cable is round；According to line footpath size, including the biggish function cable of line footpath, the lesser function of line footpath Energy cable outside, is arranged successively；The identical immediate two functions cable of line footpath is located along the straight line across the center of circle into axis pair Claim；Function cable includes:
A, active force core: including the active force cable core conductor wrapped up outside hose and hose；In active force cable core conductor Support construction is connected between hose, support construction constitutes multiple tubular conduits between active force cable core conductor and hose； The axis of each tubular conduit and the axis of cable are parallel；
The active force cable core conductor is wrapped with active force core wrapping layer, wraps up outside active force core wrapping layer actively Line of force core insulation layer；
B, wire core: wire core is constituted by wrapping up ground wire core insulating barrier outside ground wire core conductor；
C, accessory power supply core: auxiliary electricity is constituted by wrapping up auxiliary power supply line core insulation layer outside accessory power supply core copper conductor Source core；
D, the first signal core group: signal core is constituted by wrapping up signal wire core insulation layer outside signal core copper conductor；More Signal core is twisted to constitute signal core cable core, and there is filling in cable core gap；Signal core group inner restrictive coating structure is wrapped up outside signal core cable core At the first signal core group；
E, second signal core group: signal core is constituted by wrapping up signal wire core insulation layer outside signal core copper conductor；More Signal core is twisted to constitute signal core cable core, and there is filling in cable core gap；It is overlapped wrapped metal tape outside signal core cable core and constitutes metal Wrapping layer, metal wrapping layer wrap up tincopper fuse wire braided armor outside, and signal core group inner restrictive coating is wrapped up on tincopper fuse wire braided armor surface Constitute second signal core group.
The active force cable core conductor, the requirement of ground wire core conductor are identical, they are all to be twisted structure by multiply naked copper monofilament At；The diameter range of naked copper monofilament is 0.1mm~0.2mm；The twisted stranding distance of naked copper monofilament is no more than twisted rear conductor diameter 18 times, the stranding distance of per share bare copper wire is not more than 35 times of twisted rear strand outer diameter；Naked copper monofilament is annealing naked copper monofilament, naked copper list The oxygen content of copper is not more than 0.001% in silk, and 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m；
The accessory power supply core copper conductor, the requirement of signal core copper conductor are identical, they are all copper foil conductors；Copper foil Conductor is after copper foil docking dredges and is wound on fiber surface, then with copper monofilament is twisted constitutes；Copper monofilament is annealing naked copper monofilament, copper monofilament The oxygen content of middle copper is not more than 0.001%, and 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m。
In the active force core, explosion-proof enhancement layer is also wrapped up outside active force core insulating layer；Explosion-proof enhancement layer is by gold Category is constituted with wrapped composition, or by metal wire knitted, or is made of fiber filament braiding.
Structure in the first signal core group, between signal core cable core and signal core group inner restrictive coating are as follows: signal core cable It is overlapped wrapped metal tape outside core and constitutes metal wrapping layer, tincopper fuse wire braided armor, tinned copper wire braiding are wrapped up outside metal wrapping layer Layer is outer to wrap up signal core group inner restrictive coating.
The Duplication of metal wrapping layer is not less than 25%；The braided wires diameter of tincopper fuse wire braided armor is not more than 0.15mm, Count 80%~90%.
The requirement of reticular structure are as follows: mesh density is not less than 80%, and wire is tinned copper wire or bare copper wire, wherein plating 20 DEG C of resistivity of tin copper wire≤0.01780 Ω mm2/m, 20 DEG C of resistivity of bare copper wire≤0.017241 Ω mm2/m；Netted knot The elongation of structure is not less than 15%；
Separation layer is that environmentally friendly non-absorbent material is constituted, and separation layer thickness is not more than 0.1mm.
Inner sheath is wrapped up outside non-woven fabrics outside the big cable core, and the reticular structure that wire is constituted, net are wrapped up outside inner sheath There is separation layer outside shape structure, wraps up oversheath outside separation layer again.
The support construction is to be extruded to constitute by thermoplastic elastic material.
Above-mentioned cable encounters problem in actual production: due to using new structure, using traditional processing technology, or It is that empirically equal be modified on traditional processing technology can not all produce the cable for reaching theoretical performance, or even can not give birth to Produce the cable for meeting custom requirements.For this purpose, the invention proposes a kind of new manufacturing method, it is exclusively used in the cable, specifically such as Under:
A kind of manufacturing method of fluid insulation cable, step include:
1) conductor strand and copper foil conductor are first manufactured:
A, conductor strand: being to constitute conductor by multiply naked copper monofilament is twisted；The diameter range of naked copper monofilament be 0.1mm~ 0.2mm；The twisted stranding distance of naked copper monofilament is no more than 18 times of twisted rear conductor diameter, and the stranding distance of per share bare copper wire is no more than twisted 35 times of strand outer diameter afterwards；Naked copper monofilament is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001%, 20 in naked copper monofilament DEG C volume resistivity is not more than 0.01701 Ω .mm2/m；It is spare；
B, it copper foil conductor: is dredged by copper foil docking after being wound on fiber surface, then is twisted with copper monofilament and constitutes copper foil conductor；Copper list Silk is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001% in copper monofilament, and 20 DEG C of volume resistivities are not more than 0.01701 Ω.mm2/m。
It is standby respectively as accessory power supply core copper conductor and signal core group copper conductor according to the line footpath size of copper foil conductor With；
2) manufacture of each function cable:
2.1) it manufactures active force core: taking hose, thermoplastic elastic material is crowded to constitute support using extruding outside hose Structure；Conductor strand is wrapped up outside support construction again, constitutes active force cable core conductor；It is wrapped up outside active force cable core conductor again Active force core wrapping layer extrudes thermo-setting elastomer Insulation Material outside active force core wrapping layer and obtains the insulation of active force core Layer, wraps up explosion-proof enhancement layer outside active force core insulating layer, spare；
Explosion-proof enhancement layer is to be constituted by metal tape is wrapped, or be made of metal wire knitted, or compiled by fiber filament It is configured to；
2.2) it manufactures wire core: after taking conductor strand made from step 1) to be twisted again, and extruding thermosetting property bullet outside it Property body Insulation Material；It is spare；
2.3) it manufactures accessory power supply core: taking copper foil conductor made from step 1), extrude heat cured insulation material outside it, it is standby With；
2.4) it manufactures the first signal core group: taking copper foil conductor made from step 1), heat cured insulation material, structure are extruded outside it At signal core；More signal cores and the twisted composition signal core cable core of gasket for packing, lay ratio are not more than 20 times；Signal core cable Signal core group inner restrictive coating is wrapped up outside core constitutes the first signal core group；
2.5) it manufactures second signal core group: taking copper foil conductor made from step 1), heat cured insulation material, structure are extruded outside it At signal core；
More signal cores and the twisted composition signal core cable core of gasket for packing, lay ratio are not more than 20 times；Signal core cable core The outer wrapped aluminium foil strip of overlapping, wrapped overlap rate are not less than 25%；Tincopper fuse wire braided armor, tinned copper wire are wrapped up outside aluminium foil strip again Diameter is not more than 0.15mm, and count is 80%~90%；Inner restrictive coating is finally wrapped up outside tincopper fuse wire braided armor, it is standby With；
In first and second signal core group, signal core twisting pitch is different；
3) step 2.1~2.5) made from after function cable and gasket for packing be twisted into big cable core jointly, further around packet nonwoven Strap:
Stranding twisting pitch range is outer diameter after 12~16 times of cores are twisted；
85~90r/min of cage revolving speed (preferably 92.2r/min) of cable-former, 4~5m/min of hauling speed (preferably 4m/ Min), 10~20r/min of taping head revolving speed；
Wrapped overlap rate is overlapped not less than 25% with nonwoven fabric belts；When wrapped, hauling speed is 4~5m/min, wrapped Pitch is 40 ± 5mm, and the tension on nonwoven fabric belts is 40~45N (preferably 40N)；Lapping direction is dextrad, nonwoven fabric belts thickness For 0.1mm；
Thermoplastic elastomer sheath material is extruded outside nonwoven fabric belts and constitutes inner sheath, and the thickness of inner sheath is not less than 0.5mm；
Metal mesh shaped structure is wrapped up outside inner sheath；The mesh density of reticular structure is not less than 80%, and wire is tin plating Copper wire or bare copper wire, wherein 20 DEG C of resistivity of tinned copper wire≤0.01780 Ω mm2/ m, 20 DEG C of resistivity of bare copper wire≤ 0.017241Ω·mm2/m；The elongation of reticular structure is not less than 15%；
Separation layer is wrapped up in metal mesh shaped structure baby again, separation layer is that environmentally friendly non-absorbent material is constituted, and thickness is isolated Degree is not more than 0.1mm.
4) outer elastomer sheathing material is extruded outside nonwoven fabric belts.
In each step, thermo-setting elastomer Insulation Material extrudes requirement are as follows:
From discharging direction is fed to, extruding machine fuselage warm area is respectively as follows: 145 ± 5 DEG C of an area, 150 ± 5 DEG C of 2nd area, 3rd area 160 ± 5 DEG C, 170 ± 5 DEG C of 4th area, 180 ± 5 DEG C of 5th area；The temperature of each warm area of head and machine neck is all 185 ± 5 DEG C；
Wherein: an area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone；
Insulation Material accelerates to complete to irradiate after squeezing out by electronics, 1.2~2.1MEV of irradiation energy, line 20mA~26mA, Energy ratio 1.2~2.0,30~120m/min of line speed；
In each step, the requirement that extrudes of thermoplastic elastic material is to match mold core, die sleeve on the head of extruding machine, Mold core aperture=conductor diameter+0.2mm；From being fed to discharging direction, extruding machine fuselage warm area be respectively as follows: 145 ± 5 DEG C of an area, Two 155 ± 5 DEG C of areas, 165 ± 5 DEG C of 3rd area, 175 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area；The temperature of each warm area of head and machine neck Degree is all 190 ± 5 DEG C；
Wherein: an area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone.
It further include step in the step 2.4) are as follows: it is wrapped that wrapped aluminium foil strip composition metal is overlapped outside signal core cable core Layer, metal wrapping layer wrap up tincopper fuse wire braided armor outside, and signal core group inner restrictive coating is finally wrapped up outside tincopper fuse wire braided armor； The wrapped overlap rate of aluminium foil strip is not less than 25%；In tincopper fuse wire braided armor, tinned copper wire diameter is not more than 0.15mm, weaves close Spend who 80%~90%.
The twisted equipment of big cable core can use back-twisting cable-former, such as 3+6 cable-former.The stranding wire parallel module of cable-former Using tungsten steel die, internal orifice dimension is equal to core and is twisted outer diameter, and stranding direction is dextrad；Cable core gap is added using non-hygroscopic high temperature resistant Twist profiles gasket for packing；Gasket for packing fills diameter and uses 9 4.0mm.
In the step 4), oversheath is obtained using extruding machine extrude sheath material, and an area is pan feeding section, 2nd area, 3rd area For fluxing zone, 4th area, 5th area are that homogenizing zone is fed to discharging direction, discharging direction, fuselage warm area certainly are as follows: 145 ± 5 DEG C of an area, Two 155 ± 5 DEG C of areas, 165 ± 5 DEG C of 3rd area, 175 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area；Head, machine neck each warm area temperature It is all 195 ± 5 DEG C；
One area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone.
In the step 1) A, during the process of conductor, the hauling speed of conductor is 9.696 ± 2m/min, draws revolving speed It is 10~15 grades.By taking 1+6+12+18 disk hauling cage machine as an example, 1+6 cage revolving speed is (76 ± 3) r/min, and 12 disk cage revolving speeds are (75.9 ± 3) r/min, 18 disk cage revolving speeds are (66 ± 3) r/min, and twisted wire outermost layer pitch is not more than 160mm.
Thermo-setting elastomer insulating materials be EVA substrate, cooperation cooperation toughened system, flame-retardant system, preventing aging system and Lubricating system is formed through physics and chemical modification, and tear resistance is not less than 15N/mm, and water resistance is wanted by 80 DEG C × 168 tests It asks, insulation hardness is not less than 90 shore A, and 3670M Ω km is not less than at 20 DEG C of insulation resistance constant, and insulation tensile strength is not small It is not less than 300% in 10MPa, elongation at break, 158 DEG C, 168h postcondition, variation in tensile strength are not more than ± 30%, break Split elongation change rate no more than ± 30%, under the conditions of -40 DEG C, elongation at break is not less than 30%, and 90 DEG C of whens are not less than 3.67, High temperature pressure impression is not more than 50% under the conditions of 90 DEG C；It is shunk under the conditions of 130 DEG C and is not more than 4%, be not precipitated, is halogen-free, without red Phosphorus meets environmental protection and REACH requirement.
Cable conductor surface insulation layer accelerates to complete irradiation, 1.2~2.1MEV of irradiation energy, line by electronics after squeezing out 20mA~26mA, energy ratio 1.2~2.0,30~120m/min of line speed.After it takes insulating layer sample preparation after irradiating, 250 Under the conditions of DEG C, 15min, elongation at break be not more than 100%, permanent set be not more than ± 25%
In step 3, packing material is high temperature resistant, twisting type gasket for packing, and the main substrate of the gasket for packing is polypropylene material, Various sizes of gasket for packing is placed for gap different in cable core；In addition, the packing material insulation under the conditions of 125 DEG C, Phenomena such as 240h, material can not deform, aging, decomposition, fragmentation, still keep original good form.
In step 4), protective cover material is cooperation toughened system, flame-retardant system, preventing aging system and profit using elastomer as substrate Gliding mass system is changed to through physics and chemistry, has good flexibility, oil resistant, wear-resisting, anti-UV, hydrolysis, acid and alkali-resistance are fire-retardant excellent More, it is not precipitated, is halogen-free, no red phosphorus, the weather of resistance to 720h, by single vertical combustion test, tearing toughness is not less than 20N/ mm.Under the conditions of 105 DEG C, 4h, the slippage power of cable still keeps 500N or more.
Insulating layer material requires as high electrical, ageing-resistant, resistance to -40 DEG C of low temperature, hydrolysis, chemically-resistant liquid.
The protective cover material requirement of restrictive coating are as follows: high anti-tear, high abrasion, water-fast, weather-proof, resistance to -40 DEG C of low temperature, fire-retardant, environmentally friendly, resistance to Chemical liquid, antiultraviolet.
Ground wire core insulating barrier, auxiliary core, signal wire core insulation layer material are as follows: high rigidity, high electrical, resistance to -40 DEG C of low temperature, Ageing-resistant, fire-retardant and thermosetting property.
This cable passes through the particular design of material, structure etc., is full of in charging time 15min, and continue a journey 400km, cable weight Amount, outer diameter reduce, and charging fever temperature rise is less than 10 DEG C.Using cable made from this method, it is able to satisfy design requirement, meanwhile, it closes Lattice rate reaches 98% or more.Active force insulated wire cores conductor declines 50% or more, is full of in charging time 15min, cable weight, Outer diameter reduces, the application of the technology, and the bottleneck problem of solution China's new-energy automobile charging time length that can be inexpensive is conducive to The popularization and use of new-energy automobile.
Detailed description of the invention
Fig. 1 is the radial cross section of the present embodiment cable,
In figure: active force core 1, hose 2, active force cable core conductor 3, support construction 4, wire core 5, ground wire core conductor 6, Ground wire core insulating barrier 7, accessory power supply core 8, accessory power supply core copper conductor 9, auxiliary power supply line core insulation layer 10, the first signal Core group 11, signal core copper conductor 12, signal wire core insulation layer 13, second signal core group 14, oversheath 15.
Specific embodiment
The technical program is further described below combined with specific embodiments below:
Such as Fig. 1, a kind of liquid insulation cable is made of big cable core more root functionality cable twists, and big cable core gap is by gasket for packing Filling；Wrapped nonwoven fabric belts, which are overlapped, outside big cable core constitutes nonwoven layer；Oversheath is wrapped up outside nonwoven layer, constitutes cable；
The radial section of cable is round；According to line footpath size, including the biggish function cable of line footpath, the lesser function of line footpath Energy cable outside, is arranged successively；The identical immediate two functions cable of line footpath is located along the straight line across the center of circle into axis pair Claim；Function cable includes:
A, active force core: including the active force cable core conductor wrapped up outside hose and hose；In active force cable core conductor Support construction is connected between hose, support construction constitutes multiple tubular conduits between active force cable core conductor and hose； The axis of each tubular conduit and the axis of cable are parallel；
The active force cable core conductor is wrapped with active force core wrapping layer, wraps up outside active force core wrapping layer actively Line of force core insulation layer；
B, wire core: wire core is constituted by wrapping up ground wire core insulating barrier outside ground wire core conductor；
C, accessory power supply core: auxiliary electricity is constituted by wrapping up auxiliary power supply line core insulation layer outside accessory power supply core copper conductor Source core；
D, the first signal core group: signal core is constituted by wrapping up signal wire core insulation layer outside signal core copper conductor；More Signal core is twisted to constitute signal core cable core, and there is filling in cable core gap；Signal core group inner restrictive coating structure is wrapped up outside signal core cable core At the first signal core group；
E, second signal core group: signal core is constituted by wrapping up signal wire core insulation layer outside signal core copper conductor；More Signal core is twisted to constitute signal core cable core, and there is filling in cable core gap；It is overlapped wrapped metal tape outside signal core cable core and constitutes metal Wrapping layer, metal wrapping layer wrap up tincopper fuse wire braided armor outside, and signal core group inner restrictive coating is wrapped up on tincopper fuse wire braided armor surface Constitute second signal core group.
The active force cable core conductor, the requirement of ground wire core conductor are identical, they are all to be twisted structure by multiply naked copper monofilament At；The diameter range of naked copper monofilament is 0.1mm~0.2mm；The twisted stranding distance of naked copper monofilament is no more than twisted rear conductor diameter 18 times, the stranding distance of per share bare copper wire is not more than 35 times of twisted rear strand outer diameter；Naked copper monofilament is annealing naked copper monofilament, naked copper list The oxygen content of copper is not more than 0.001% in silk, and 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m；
The accessory power supply core copper conductor, the requirement of signal core copper conductor are identical, they are all copper foil conductors；Copper foil Conductor is after copper foil docking dredges and is wound on fiber surface, then with copper monofilament is twisted constitutes；Copper monofilament is annealing naked copper monofilament, copper monofilament The oxygen content of middle copper is not more than 0.001%, and 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m。
In the active force core, explosion-proof enhancement layer is also wrapped up outside active force core insulating layer；Explosion-proof enhancement layer is by gold Category is constituted with wrapped composition, or by metal wire knitted, or is made of fiber filament braiding.
Structure in the first signal core group, between signal core cable core and signal core group inner restrictive coating are as follows: signal core cable It is overlapped wrapped metal tape outside core and constitutes metal wrapping layer, tincopper fuse wire braided armor, tinned copper wire braiding are wrapped up outside metal wrapping layer Layer is outer to wrap up signal core group inner restrictive coating.
The Duplication of metal wrapping layer is not less than 25%；The braided wires diameter of tincopper fuse wire braided armor is not more than 0.15mm, Count 80%~90%.
The requirement of reticular structure are as follows: mesh density is not less than 80%, and wire is tinned copper wire or bare copper wire, wherein plating 20 DEG C of resistivity of tin copper wire≤0.01780 Ω mm2/m, 20 DEG C of resistivity of bare copper wire≤0.017241 Ω mm2/m；Netted knot The elongation of structure is not less than 15%；
Separation layer is that environmentally friendly non-absorbent material is constituted, and separation layer thickness is not more than 0.1mm.
Inner sheath is wrapped up outside non-woven fabrics outside the big cable core, and the reticular structure that wire is constituted, net are wrapped up outside inner sheath There is separation layer outside shape structure, wraps up oversheath outside separation layer again.
The support construction is to be extruded to constitute by thermoplastic elastic material.
The manufacturing method of this example cable, step include:
1) conductor strand and copper foil conductor are first manufactured:
A, conductor strand: being to constitute conductor by multiply naked copper monofilament is twisted；The diameter range of naked copper monofilament be 0.1mm~ 0.2mm；The twisted stranding distance of naked copper monofilament is no more than 18 times of twisted rear conductor diameter, and the stranding distance of per share bare copper wire is no more than twisted 35 times of strand outer diameter afterwards；Naked copper monofilament is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001%, 20 in naked copper monofilament DEG C volume resistivity is not more than 0.01701 Ω .mm2/m；It is spare；
B, it copper foil conductor: is dredged by copper foil docking after being wound on fiber surface, then is twisted with copper monofilament and constitutes copper foil conductor；Copper list Silk is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001% in copper monofilament, and 20 DEG C of volume resistivities are not more than 0.01701 Ω.mm2/m。
It is standby respectively as accessory power supply core copper conductor and signal core group copper conductor according to the line footpath size of copper foil conductor With；
2) manufacture of each function cable:
2.1) it manufactures active force core: taking hose, thermoplastic elastic material is crowded to constitute support using extruding outside hose Structure；Conductor strand is wrapped up outside support construction again, constitutes active force cable core conductor；It is wrapped up outside active force cable core conductor again Active force core wrapping layer extrudes thermo-setting elastomer Insulation Material outside active force core wrapping layer and obtains the insulation of active force core Layer, wraps up explosion-proof enhancement layer outside active force core insulating layer, spare；
Explosion-proof enhancement layer is to be constituted by metal tape is wrapped, or be made of metal wire knitted, or compiled by fiber filament It is configured to；
2.2) it manufactures wire core: after taking conductor strand made from step 1) to be twisted again, and extruding thermosetting property bullet outside it Property body Insulation Material；It is spare；
2.3) it manufactures accessory power supply core: taking copper foil conductor made from step 1), extrude heat cured insulation material outside it, it is standby With；
2.4) it manufactures the first signal core group: taking copper foil conductor made from step 1), heat cured insulation material, structure are extruded outside it At signal core；More signal cores and the twisted composition signal core cable core of gasket for packing, lay ratio are not more than 20 times；Signal core cable Signal core group inner restrictive coating is wrapped up outside core constitutes the first signal core group；
2.5) it manufactures second signal core group: taking copper foil conductor made from step 1), heat cured insulation material, structure are extruded outside it At signal core；
More signal cores and the twisted composition signal core cable core of gasket for packing, lay ratio are not more than 20 times；Signal core cable core The outer wrapped aluminium foil strip of overlapping, wrapped overlap rate are not less than 25%；Tincopper fuse wire braided armor, tinned copper wire are wrapped up outside aluminium foil strip again Diameter is not more than 0.15mm, and count is 80%~90%；Inner restrictive coating is finally wrapped up outside tincopper fuse wire braided armor, it is standby With；
In first and second signal core group, signal core twisting pitch is different；
3) step 2.1~2.5) made from after function cable and gasket for packing be twisted into big cable core jointly, further around packet nonwoven Strap:
Stranding twisting pitch range is outer diameter after 12~16 times of cores are twisted；
85~90r/min of cage revolving speed (preferably 92.2r/min) of cable-former, 4~5m/min of hauling speed (preferably 4m/ Min), 10~20r/min of taping head revolving speed；
Wrapped overlap rate is overlapped not less than 25% with nonwoven fabric belts；When wrapped, hauling speed is 4~5m/min, wrapped Pitch is 40 ± 5mm, and the tension on nonwoven fabric belts is 40~45N (preferably 40N)；Lapping direction is dextrad, nonwoven fabric belts thickness For 0.1mm；
Thermoplastic elastomer sheath material is extruded outside nonwoven fabric belts and constitutes inner sheath, and the thickness of inner sheath is not less than 0.5mm；
Metal mesh shaped structure is wrapped up outside inner sheath；The mesh density of reticular structure is not less than 80%, and wire is tin plating Copper wire or bare copper wire, wherein 20 DEG C of resistivity of tinned copper wire≤0.01780 Ω mm2/ m, 20 DEG C of resistivity of bare copper wire≤ 0.017241Ω·mm2/m；The elongation of reticular structure is not less than 15%；
Separation layer is wrapped up in metal mesh shaped structure baby again, separation layer is that environmentally friendly non-absorbent material is constituted, and thickness is isolated Degree is not more than 0.1mm.
4) outer elastomer sheathing material is extruded outside nonwoven fabric belts.
In each step, thermo-setting elastomer Insulation Material extrudes requirement are as follows:
From discharging direction is fed to, extruding machine fuselage warm area is respectively as follows: 145 ± 5 DEG C of an area, 150 ± 5 DEG C of 2nd area, 3rd area 160 ± 5 DEG C, 170 ± 5 DEG C of 4th area, 180 ± 5 DEG C of 5th area；The temperature of each warm area of head and machine neck is all 185 ± 5 DEG C；
Wherein: an area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone；
Insulation Material accelerates to complete to irradiate after squeezing out by electronics, 1.2~2.1MEV of irradiation energy, line 20mA~26mA, Energy ratio 1.2~2.0,30~120m/min of line speed；
In each step, the requirement that extrudes of thermoplastic elastic material is to match mold core, die sleeve on the head of extruding machine, Mold core aperture=conductor diameter+0.2mm；From being fed to discharging direction, extruding machine fuselage warm area be respectively as follows: 145 ± 5 DEG C of an area, Two 155 ± 5 DEG C of areas, 165 ± 5 DEG C of 3rd area, 175 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area；The temperature of each warm area of head and machine neck Degree is all 190 ± 5 DEG C；
Wherein: an area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone.
It further include step in the step 2.4) are as follows: it is wrapped that wrapped aluminium foil strip composition metal is overlapped outside signal core cable core Layer, metal wrapping layer wrap up tincopper fuse wire braided armor outside, and signal core group inner restrictive coating is finally wrapped up outside tincopper fuse wire braided armor； The wrapped overlap rate of aluminium foil strip is not less than 25%；In tincopper fuse wire braided armor, tinned copper wire diameter is not more than 0.15mm, weaves close Spend who 80%~90%.
The twisted equipment of big cable core can use back-twisting cable-former, such as 3+6 cable-former.The stranding wire parallel module of cable-former Using tungsten steel die, internal orifice dimension is equal to core and is twisted outer diameter, and stranding direction is dextrad；Cable core gap is added using non-hygroscopic high temperature resistant Twist profiles gasket for packing；Gasket for packing fills diameter and uses 9 4.0mm.
In the step 4), oversheath is obtained using extruding machine extrude sheath material, and an area is pan feeding section, 2nd area, 3rd area For fluxing zone, 4th area, 5th area are that homogenizing zone is fed to discharging direction, discharging direction, fuselage warm area certainly are as follows: 145 ± 5 DEG C of an area, Two 155 ± 5 DEG C of areas, 165 ± 5 DEG C of 3rd area, 175 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area；Head, machine neck each warm area temperature It is all 195 ± 5 DEG C；
One area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone.
In the step 2.1), in hose outer surface during process conductor, the hauling speed of cable is 9.696 ± 2m/min, traction revolving speed are 10~15 grades.By taking 1+6+12+18 disk hauling cage machine as an example, 1+6 cage revolving speed is (76 ± 3) r/min, 12 disk cage revolving speeds are (75.9 ± 3) r/min, and 18 disk cage revolving speeds are (66 ± 3) r/min, and twisted wire outermost layer pitch is not more than 160mm。
Thermo-setting elastomer insulating materials be EVA substrate, cooperation cooperation toughened system, flame-retardant system, preventing aging system and Lubricating system is formed through physics and chemical modification, and tear resistance is not less than 15N/mm, and water resistance is wanted by 80 DEG C × 168 tests It asks, insulation hardness is not less than 90 shore A, and 3670M Ω km is not less than at 20 DEG C of insulation resistance constant, and insulation tensile strength is not small It is not less than 300% in 10MPa, elongation at break, 158 DEG C, 168h postcondition, variation in tensile strength are not more than ± 30%, break Split elongation change rate no more than ± 30%, under the conditions of -40 DEG C, elongation at break is not less than 30%, and 90 DEG C of whens are not less than 3.67, High temperature pressure impression is not more than 50% under the conditions of 90 DEG C；It is shunk under the conditions of 130 DEG C and is not more than 4%, be not precipitated, is halogen-free, without red Phosphorus meets environmental protection and REACH requirement.
Conductor surface insulation layer accelerates to complete irradiation, 1.2~2.1MEV of irradiation energy, line 20mA by electronics after squeezing out ~26mA, energy ratio 1.2~2.0,30~120m/min of line speed.After it takes insulating layer sample preparation after irradiating, in 250 DEG C of items Under part, 15min, elongation at break be not more than 100%, permanent set be not more than ± 25%；
In step 3, packing material is high temperature resistant, twisting type gasket for packing, and the main substrate of the gasket for packing is polypropylene material, Various sizes of gasket for packing is placed for gap different in cable core；In addition, the packing material insulation under the conditions of 125 DEG C, Phenomena such as 240h, material can not deform, aging, decomposition, fragmentation, still keep original good form.
In step 4), protective cover material is cooperation toughened system, flame-retardant system, preventing aging system and profit using elastomer as substrate Gliding mass system is changed to through physics and chemistry, has good flexibility, oil resistant, wear-resisting, anti-UV, hydrolysis, acid and alkali-resistance are fire-retardant excellent More, it is not precipitated, is halogen-free, no red phosphorus, the weather of resistance to 720h, by single vertical combustion test, tearing toughness is not less than 20N/ mm.Under the conditions of 105 DEG C, 4h, the slippage power of cable still keeps 500N or more.
Insulating layer material requires as high electrical, ageing-resistant, resistance to -40 DEG C of low temperature, hydrolysis, chemically-resistant liquid.
The protective cover material requirement of restrictive coating are as follows: high anti-tear, high abrasion, water-fast, weather-proof, resistance to -40 DEG C of low temperature, fire-retardant, environmentally friendly, resistance to Chemical liquid, antiultraviolet.
Ground wire core insulating barrier, auxiliary core, signal wire core insulation layer material are as follows: high rigidity, high electrical, resistance to -40 DEG C of low temperature, Ageing-resistant, fire-retardant and thermosetting property.
Wherein, in the selection of above-mentioned technological parameter, when selecting median and preferred value, an excellent rate of product When reaching 99.6%, and relax in value range, although the available product that conforms to quality requirements, one time excellent rate exists more Between 98~99%.
As a result it detects, the characteristics of this cable includes:
1) charging time shortens
DC charging foreshortens to 15min, realizes that electric car is continued a journey 400 kilometers, the cable charging time shortens 90%.
2) cable purchase cost reduces: cable buying drop sheet 15%~20%.
3) cable weight mitigation, outer diameter are small
The control of this outside diameter of cable is in 46mm hereinafter, the 400A direct current charging cable finished cable weight decline 25% that compares.
4) temperature rise is small
This cable is full of in 15min, realizes that electric car is continued a journey 400 kilometers, temperature rise is no more than 35 DEG C.
5) high electrical
The product of inspection is detected through third party's pattern, actual measurement insulation, the volume resistivity actual measurement 10 of sheath15Ω .mm, is filled up The world ISO, GB country new-energy automobile silicon rubber car high pressure 109Ω.mm。
6) high and low temperature resistance
Active force power supply meets 125 DEG C of operating conditions and uses.Meet -40 DEG C of low-temperature impacts, -40 DEG C of low temperature windings, -40 DEG C of low temperature Tension test requirement.
7) fire retardancy test:
Meet the single burning of GB/T18380.12.
8) chemical-resistant reagent
Meet method one, the method two, battery acid test requirements document in ISO6722-1 standard simultaneously, meets working condition requirement.
9) resistance to vehicle rolls
This cable is rolled through vehicle reciprocal 3 times, is applied voltage tester, cooling cycle test, is met and reuse.

Claims (10)

1. a kind of manufacturing method of fluid insulation cable, step include:
1) conductor strand and copper foil conductor are first manufactured:
A, conductor strand: being to constitute conductor by multiply naked copper monofilament is twisted；The diameter range of naked copper monofilament be 0.1mm~ 0.2mm；The twisted stranding distance of naked copper monofilament is no more than 18 times of twisted rear conductor diameter, and the stranding distance of per share bare copper wire is no more than twisted 35 times of strand outer diameter afterwards；Naked copper monofilament is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001%, 20 in naked copper monofilament DEG C volume resistivity is not more than 0.01701 Ω .mm2/m；It is spare；
B, it copper foil conductor: is dredged by copper foil docking after being wound on fiber surface, then is twisted with copper monofilament and constitutes copper foil conductor；Copper monofilament is It anneals naked copper monofilament, the oxygen content of copper is not more than 0.001% in copper monofilament, and 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m。
It is spare respectively as accessory power supply core copper conductor and signal core group copper conductor according to the line footpath size of copper foil conductor；
2) manufacture of each function cable:
2.1) it manufactures active force core: taking hose, thermoplastic elastic material is crowded to constitute support construction using extruding outside hose； Conductor strand is wrapped up outside support construction again, constitutes active force cable core conductor；It is wrapped up outside active force cable core conductor again actively Line of force core wrapping layer extrudes thermo-setting elastomer Insulation Material outside active force core wrapping layer and obtains active force core insulating layer, Explosion-proof enhancement layer is wrapped up outside active force core insulating layer, it is spare；
Explosion-proof enhancement layer is to be constituted by metal tape is wrapped, or be made of metal wire knitted, or weave structure by fiber filament At；
2.2) it manufactures wire core: after taking conductor strand made from step 1) to be twisted again, and extruding thermo-setting elastomer outside it Insulation Material；It is spare；
2.3) it manufactures accessory power supply core: taking copper foil conductor made from step 1), extrude heat cured insulation material outside it, it is spare；
2.4) it manufactures the first signal core group: taking copper foil conductor made from step 1), heat cured insulation material is extruded outside it, constitute letter Number core；More signal cores and the twisted composition signal core cable core of gasket for packing, lay ratio are not more than 20 times；Outside signal core cable core It wraps up signal core group inner restrictive coating and constitutes the first signal core group；
2.5) it manufactures second signal core group: taking copper foil conductor made from step 1), heat cured insulation material is extruded outside it, constitute letter Number core；
More signal cores and the twisted composition signal core cable core of gasket for packing, lay ratio are not more than 20 times；Weight outside signal core cable core Lap wound aluminium foil band, wrapped overlap rate are not less than 25%；Tincopper fuse wire braided armor, tinned copper wire diameter are wrapped up outside aluminium foil strip again No more than 0.15mm, count is 80%~90%；Inner restrictive coating is finally wrapped up outside tincopper fuse wire braided armor, it is spare；
In first and second signal core group, signal core twisting pitch is different；
3) step 2.1~2.5) made from after function cable and gasket for packing be twisted into big cable core jointly, further around packet nonwoven fabric belts:
Stranding twisting pitch range is outer diameter after 12~16 times of cores are twisted；
Cage 85~the 90r/min of revolving speed, 4~5m/min of hauling speed, 10~20r/min of taping head revolving speed of cable-former；
Wrapped overlap rate is overlapped not less than 25% with nonwoven fabric belts；When wrapped, hauling speed is 4~5m/min, lay of lapping For 40 ± 5mm, the tension on nonwoven fabric belts is 40~45N；Lapping direction is dextrad, and nonwoven fabric belts are with a thickness of 0.1mm；
Thermoplastic elastomer sheath material is extruded outside nonwoven fabric belts and constitutes inner sheath, and the thickness of inner sheath is not less than 0.5mm；
Metal mesh shaped structure is wrapped up outside inner sheath；The mesh density of reticular structure is not less than 80%, and wire is tinned copper wire Or bare copper wire, wherein 20 DEG C of resistivity of tinned copper wire≤0.01780 Ω mm2/ m, 20 DEG C of resistivity≤0.017241 of bare copper wire Ω·mm2/m；The elongation of reticular structure is not less than 15%；
Separation layer is wrapped up in metal mesh shaped structure baby again, separation layer is that environmentally friendly non-absorbent material is constituted, and separation layer thickness is not Greater than 0.1mm.
4) outer elastomer sheathing material is extruded outside nonwoven fabric belts.
2. cable making method according to claim 1, it is characterized in that in each step, thermo-setting elastomer Insulation Material Extrude requirement are as follows:
From being fed to discharging direction, extruding machine fuselage warm area be respectively as follows: 145 ± 5 DEG C of an area, 150 ± 5 DEG C of 2nd area, three areas 160 ± 5 DEG C, 170 ± 5 DEG C of 4th area, 180 ± 5 DEG C of 5th area；The temperature of each warm area of head and machine neck is all 185 ± 5 DEG C；
Wherein: an area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone；
Insulation Material accelerates to complete irradiation, 1.2~2.1MEV of irradiation energy, line 20mA~26mA, energy by electronics after squeezing out Than 1.2~2.0,30~120m/min of line speed；
In each step, the requirement that extrudes of thermoplastic elastic material is to match mold core, die sleeve, mold core on the head of extruding machine Aperture=conductor diameter+0.2mm；From discharging direction is fed to, extruding machine fuselage warm area is respectively as follows: 145 ± 5 DEG C of an area, 2nd area 155 ± 5 DEG C, 165 ± 5 DEG C of 3rd area, 175 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area；The temperature of each warm area of head and machine neck is all It is 190 ± 5 DEG C；
Wherein: an area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone；
In the step 4), oversheath is obtained using extruding machine extrude sheath material, and an area is pan feeding section, and 2nd area, 3rd area are modeling Change section, 4th area, 5th area are that homogenizing zone is fed to discharging direction, discharging direction, fuselage warm area certainly are as follows: 145 ± 5 DEG C of an area, 2nd area 155 ± 5 DEG C, 165 ± 5 DEG C of 3rd area, 175 ± 5 DEG C of 4th area, 185 ± 5 DEG C of 5th area；Head, machine neck the temperature of each warm area be all 195±5℃；
One area is pan feeding section, and 2nd area, 3rd area are fluxing zone, and 4th area, 5th area are homogenizing zone.
3. cable making method according to claim 1, it is characterized in that further including step in the step 2.4) are as follows: believing It is overlapped wrapped aluminium foil strip outside number core cable core and constitutes metal wrapping layer, wraps up tincopper fuse wire braided armor outside metal wrapping layer, finally exists Signal core group inner restrictive coating is wrapped up outside tincopper fuse wire braided armor；The wrapped overlap rate of aluminium foil strip is not less than 25%；Tinned copper wire is compiled In tissue layer, tinned copper wire diameter be not more than 0.15mm, count who 80%~90%.
4. cable making method according to claim 1, it is characterized in that in the step 1) A, during the process of conductor, The hauling speed of conductor is 9.696 ± 2m/min, and traction revolving speed is 10~15 grades.
5. cable made from a kind of claim 1 the method, it is characterized in that constituting big cable core by more root functionality cable twists, greatly It is filled by gasket for packing in cable core gap；Wrapped nonwoven fabric belts, which are overlapped, outside big cable core constitutes nonwoven layer；Outer shield is wrapped up outside nonwoven layer Set constitutes cable；Inner sheath is wrapped up outside non-woven fabrics outside the big cable core, and the netted knot that wire is constituted is wrapped up outside inner sheath Structure, reticular structure have separation layer outside, wrap up oversheath outside separation layer again；
The radial section of cable is round；According to line footpath size, including the biggish function cable of line footpath, the lesser functional line of line footpath Cable outside, is arranged successively；The identical immediate two functions cable of line footpath is located along the straight line across the center of circle into axial symmetry；Function Can cable include:
A, active force core: including the active force cable core conductor wrapped up outside hose and hose；Active force cable core conductor with it is soft Support construction is connected between pipe, support construction constitutes multiple tubular conduits between active force cable core conductor and hose；It is each The axis of tubular conduit and the axis of cable are parallel；
The active force cable core conductor is wrapped with active force core wrapping layer, wraps up active force line outside active force core wrapping layer Core insulation layer；
B, wire core: wire core is constituted by wrapping up ground wire core insulating barrier outside ground wire core conductor；
C, accessory power supply core: auxiliary power supply line is constituted by wrapping up auxiliary power supply line core insulation layer outside accessory power supply core copper conductor Core；
D, the first signal core group: signal core is constituted by wrapping up signal wire core insulation layer outside signal core copper conductor；More signals Core is twisted to constitute signal core cable core, and there is filling in cable core gap；Signal core group inner restrictive coating is wrapped up outside signal core cable core constitutes the One signal core group；
E, second signal core group: signal core is constituted by wrapping up signal wire core insulation layer outside signal core copper conductor；More signals Core is twisted to constitute signal core cable core, and there is filling in cable core gap；It is wrapped that wrapped metal tape composition metal is overlapped outside signal core cable core Layer, metal wrapping layer wrap up tincopper fuse wire braided armor outside, and tincopper fuse wire braided armor surface is wrapped up signal core group inner restrictive coating and constituted Second signal core group.
6. cable according to claim 5, it is characterized in that the active force cable core conductor, the requirement phase of ground wire core conductor Together, they are constituted by multiply naked copper monofilament is twisted；The diameter range of naked copper monofilament is 0.1mm~0.2mm；Naked copper monofilament twists 18 times of the stranding distance of conjunction no more than twisted rear conductor diameter, 35 of stranding distance no more than strand outer diameter after being twisted of per share bare copper wire Times；Naked copper monofilament is annealing naked copper monofilament, and the oxygen content of copper is not more than 0.001% in naked copper monofilament, and 20 DEG C of volume resistivities are not Greater than 0.01701 Ω .mm2/m；
The accessory power supply core copper conductor, the requirement of signal core copper conductor are identical, they are all copper foil conductors；Copper foil conductor Be after copper foil docking dredges and is wound on fiber surface, then with copper monofilament is twisted constitutes；Copper monofilament is annealing naked copper monofilament, copper in copper monofilament Oxygen content be not more than 0.001%, 20 DEG C of volume resistivities are not more than 0.01701 Ω .mm2/m。
7. cable according to claim 5, it is characterized in that also being wrapped outside active force core insulating layer in the active force core Wrap up in explosion-proof enhancement layer；Explosion-proof enhancement layer is to be constituted by metal tape is wrapped, or be made of metal wire knitted, or by fiber Silk braiding is constituted.
8. cable according to claim 5, it is characterized in that in the first signal core group, signal core cable core and signal core group Structure between inner restrictive coating are as follows: be overlapped wrapped metal tape outside signal core cable core and constitute metal wrapping layer, metal wrapping layer outsourcing Tincopper fuse wire braided armor is wrapped up in, wraps up signal core group inner restrictive coating outside tincopper fuse wire braided armor.
9. cable according to claim 8, it is characterized in that the Duplication of metal wrapping layer is not less than 25%；Tinned copper wire is compiled The braided wires diameter of tissue layer is not more than 0.15mm, count 80%~90%.
10. cable according to claim 5, it is characterized in that the requirement of reticular structure are as follows: mesh density is not less than 80%, gold Belonging to silk is tinned copper wire or bare copper wire, wherein 20 DEG C of resistivity of tinned copper wire≤0.01780 Ω mm2/m, 20 DEG C of electricity of bare copper wire Resistance rate≤0.017241 Ω mm2/m；The elongation of reticular structure is not less than 15%；
Separation layer is that environmentally friendly non-absorbent material is constituted, and separation layer thickness is not more than 0.1mm.
CN201811567044.7A 2018-12-19 2018-12-19 Manufacturing method of liquid insulated cable and cable Active CN109461521B (en)

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CN113096890A (en) * 2021-03-30 2021-07-09 东莞市领亚电线电缆有限公司 Manufacturing method of vehicle-mounted data cable
CN113972038A (en) * 2021-11-04 2022-01-25 江苏上上电缆集团有限公司 Manufacturing method of composite cable for special equipment

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CN106849228A (en) * 2017-01-13 2017-06-13 深圳市沃尔核材股份有限公司 Charging equipment cooling system
CN108172331A (en) * 2017-12-27 2018-06-15 江苏上上电缆集团有限公司 A kind of cooling cable making method and cable
CN208111135U (en) * 2017-12-27 2018-11-16 江苏上上电缆集团有限公司 A kind of cooling cable
CN209232432U (en) * 2018-12-19 2019-08-09 江苏上上电缆集团有限公司 A kind of fluid insulation cable

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CN202102770U (en) * 2011-06-07 2012-01-04 安徽五洲特种电缆集团有限公司 Environment-friendly flexible cable used for torsion-resisting roll canister machine
CN106849228A (en) * 2017-01-13 2017-06-13 深圳市沃尔核材股份有限公司 Charging equipment cooling system
CN108172331A (en) * 2017-12-27 2018-06-15 江苏上上电缆集团有限公司 A kind of cooling cable making method and cable
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CN113096890A (en) * 2021-03-30 2021-07-09 东莞市领亚电线电缆有限公司 Manufacturing method of vehicle-mounted data cable
CN113972038A (en) * 2021-11-04 2022-01-25 江苏上上电缆集团有限公司 Manufacturing method of composite cable for special equipment
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