CN111009348A - Watertight load-bearing comprehensive special-shaped flat cable and production method thereof - Google Patents

Watertight load-bearing comprehensive special-shaped flat cable and production method thereof Download PDF

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Publication number
CN111009348A
CN111009348A CN201911334942.2A CN201911334942A CN111009348A CN 111009348 A CN111009348 A CN 111009348A CN 201911334942 A CN201911334942 A CN 201911334942A CN 111009348 A CN111009348 A CN 111009348A
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China
Prior art keywords
extruder
cable
water
bearing
sheath
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CN201911334942.2A
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Chinese (zh)
Inventor
季少波
姜茂盛
张小平
刘波
高加云
杨小峰
陶远
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Anhui Hongyuan Special Cable Group Co ltd
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Anhui Hongyuan Special Cable Group Co ltd
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Priority to CN201911334942.2A priority Critical patent/CN111009348A/en
Publication of CN111009348A publication Critical patent/CN111009348A/en
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/08Flat or ribbon cables
    • H01B7/0807Twin conductor or cable
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00Communication cables or conductors
    • H01B11/02Cables with twisted pairs or quads
    • H01B11/06Cables with twisted pairs or quads with means for reducing effects of electromagnetic or electrostatic disturbances, e.g. screens
    • HELECTRICITY
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    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
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    • H01B13/02Stranding-up
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    • H01B13/06Insulating conductors or cables
    • H01B13/14Insulating conductors or cables by extrusion
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    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06Insulating conductors or cables
    • H01B13/14Insulating conductors or cables by extrusion
    • H01B13/148Selection of the insulating material therefor
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    • H01B13/22Sheathing; Armouring; Screening; Applying other protective layers
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    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/24Sheathing; Armouring; Screening; Applying other protective layers by extrusion
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    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/26Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
    • H01B13/2606Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by braiding
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    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/32Filling or coating with impervious material
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    • H01B13/32Filling or coating with impervious material
    • H01B13/322Filling or coating with impervious material the material being a liquid, jelly-like or viscous substance
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    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/02Disposition of insulation
    • H01B7/0275Disposition of insulation comprising one or more extruded layers of insulation
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    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/04Flexible cables, conductors, or cords, e.g. trailing cables
    • H01B7/041Flexible cables, conductors, or cords, e.g. trailing cables attached to mobile objects, e.g. portable tools, elevators, mining equipment, hoisting cables
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    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/08Flat or ribbon cables
    • H01B7/0823Parallel wires, incorporated in a flat insulating profile
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    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/08Flat or ribbon cables
    • H01B7/0861Flat or ribbon cables comprising one or more screens
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    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/08Flat or ribbon cables
    • H01B7/0869Flat or ribbon cables comprising one or more armouring, tensile- or compression-resistant elements
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    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
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    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/187Sheaths comprising extruded non-metallic layers
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    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/22Metal wires or tapes, e.g. made of steel
    • H01B7/221Longitudinally placed metal wires or tapes
    • H01B7/223Longitudinally placed metal wires or tapes forming part of a high tensile strength core
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    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/28Protection against damage caused by moisture, corrosion, chemical attack or weather
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    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/28Protection against damage caused by moisture, corrosion, chemical attack or weather
    • H01B7/2806Protection against damage caused by corrosion
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    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/28Protection against damage caused by moisture, corrosion, chemical attack or weather
    • H01B7/282Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
    • H01B7/2825Preventing penetration of fluid, e.g. water or humidity, into conductor or cable using a water impermeable sheath
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    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/28Protection against damage caused by moisture, corrosion, chemical attack or weather
    • H01B7/282Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
    • H01B7/285Preventing penetration of fluid, e.g. water or humidity, into conductor or cable by completely or partially filling interstices in the cable
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    • H01B9/00Power cables

Abstract

The invention discloses a longitudinal watertight mooring photoelectric composite cable, which comprises two groups of bearing units serving as centers, a group of power units and a group of signal units which are respectively arranged on two sides of the bearing units in parallel, and finally polyurethane is extruded to be used as an outer sheath. The invention also discloses a production method of the cable. According to the invention, the cable bearing mode is optimized by changing the cable structure, so that when the cable passes through the winding machine or the pulley block, the compression force of the power unit and the signal unit is reduced, the damage risk of the cable core is reduced, the integral water tightness and reliability of the cable are ensured, and the cable can be used as a bearing connecting cable in a frequent winding and unwinding stretching system.

Description

Watertight load-bearing comprehensive special-shaped flat cable and production method thereof
Technical Field
The invention relates to a watertight load-bearing comprehensive special-shaped flat cable and a production method thereof, belonging to the field of electric wires and cables.
Background
The flat cable is a flat cable formed by combining a plurality of core wire conductors, and compared with a round cable, the flat cable saves more space. The flat cable has the performance characteristics of light weight, acid and alkali corrosion resistance, good toughness, bending resistance, radiation resistance, high and low temperature resistance and the like, can be freely used in large-scale equipment and small-scale equipment, can be used for mechanical power transmission and can also be used as a connecting cable of mobile electricity, the flat cable is commonly used for a large-scale shore crane (ship to shore) of a deep water port, RMG (track type gantry crane), a ship loader and unloader, a palletizer crane, a stacker crane, a deep well crane, an offshore platform and other heavy-duty carrying equipment, and is usually wound on a large-scale reel or a winding machine for preventing the cable from being entangled, worn, taken off, hooked and scattered, because the common flat cable structure adopts a parallel arrangement structure, the cable core and a bearing steel wire are stressed the same, when the cable is bent by the winding machine, the internal stress of the cable core is larger, especially when the cable bears huge weight, the invention changes the cable structure, optimizes the cable bearing mode, thickens the two groups of bearing unit sheaths, ensures that the bearing units bear pressure when the cable passes through a winding machine or a pulley block, reduces the stress on the power unit and the signal unit, reduces the cable core damage risk, improves the service life and the safety of the cable, and has important social and economic meanings.
Disclosure of Invention
In order to fill the blank needed in the field, the invention provides a watertight load-bearing comprehensive special-shaped flat cable and a production method thereof, successfully solves the problem that a common load-bearing flat cable is easy to break and damage a cable core, optimizes a cable load-bearing mode by changing a cable structure, reduces the risk of damage to the cable core, improves the service life and the safety of the cable, and can be used as a load-bearing connecting cable in a frequent retracting and stretching system.
The scheme of the invention is as follows: a watertight load-bearing comprehensive special-shaped flat cable comprises a conductor,
the device also comprises a bearing unit, a power unit and a signal unit;
the cable takes the bearing unit as the center, the power unit and the signal unit are respectively arranged on two sides of the bearing unit in parallel, and polyurethane is extruded outside the bearing unit, the power unit and the signal unit to form a polyurethane outer sheath;
the conductor is externally extruded with a low-density polyethylene insulating layer to form a signal unit insulating wire core; the two strands of signal unit insulated wire cores and aramid fibers are filled and twisted in pairs and coated with water-blocking sealant to form an insulated wire core group;
the insulated wire core group is externally woven with tinned copper wires and coated with water-blocking sealant to form a shielded wire core group, and the four shielded wire core groups are added with aramid fibers to be filled and comprehensively formed into a cable and coated with water-blocking sealant to form a signal unit cable core;
a water-blocking wrapping tape isolating layer is arranged outside the signal unit cable core, a tinned round copper wire braided shielding layer is arranged outside the shielding layer, and a small polyurethane sheath II is extruded outside the shielding layer to form a signal unit;
the conductor is externally extruded with an irradiation crosslinked polyethylene insulating layer to form a power unit insulating wire core, and four strands of power unit insulating wire cores are comprehensively cabled and coated with water-blocking sealant to form a power unit cable core;
a water-blocking wrapping tape isolating layer is arranged outside the power unit cable core, and a small polyurethane sheath I is extruded outside the isolating layer to form a power unit;
two steel wire ropes extrude polyurethane (a small sheath III forms a bearing unit;
further, a plurality of strands of tinned round copper wires are stranded into a conductor and coated with a water-blocking sealant.
Further, the cross section of the cable sheath is a rectangle with four corners removed, namely a special-shaped octagonal flat sheath.
Furthermore, the signal unit and the power unit are both longitudinal watertight structures.
A production method of a watertight load-bearing comprehensive special-shaped flat cable is characterized by comprising the following steps:
step 1: the method comprises the following steps that 49 strands of tinned round copper wires are adopted for power unit wire cores, firstly, regular stranding is carried out according to a 1+7 arrangement mode, water-blocking sealant is coated on the tinned round copper wires to obtain 7 strands of twisted wire core components, the stranding direction is the right direction, the stranding pitch is 13 +/-1 mm, then 7 groups of 7 strands of twisted wire core component conductors are regularly stranded according to a 1+7 arrangement mode, water-blocking sealant is coated on the conductors to obtain power unit conductors, the stranding direction is the left direction, and the stranding pitch is 39 +/-3 mm;
the signal unit wire core is made of 7 strands of tinned round copper wires, is normally stranded according to a 1+7 arrangement mode, and is coated with a water-blocking sealant to obtain a signal unit conductor, wherein the stranding direction is the left direction, and the stranding pitch is 11 +/-1 mm;
step 2: drying the irradiation crosslinked polyethylene material at 40 +/-5 ℃ for 2 hours, and injecting the dried irradiation crosslinked polyethylene material into a plastic single-screw extruder to complete extrusion coating of an irradiation crosslinked polyethylene insulating layer, so as to prepare an insulating wire core of the power unit, wherein the insulating thickness of the insulating wire core is 0.6-0.7 mm; drying the low-density polyethylene material at 50 +/-5 ℃ for 2 hours, and injecting the dried low-density polyethylene material into a plastic single-screw extruder to complete extrusion coating of a low-density polyethylene insulating layer to obtain a signal unit insulating wire core, wherein the insulating thickness of the signal unit insulating wire core is 0.4-0.5 mm;
adopting an extrusion die in the plastic single-screw extruder, setting the temperature of a feed inlet of the extruder to be 150 +/-10 ℃, setting the temperature of a head of the extruder to be 200 +/-10 ℃, and setting the temperature to be increased in a stepped manner in a screw heating zone between the feed inlet of the extruder and the head of the extruder; aiming at the outgoing line of the insulated wire core from the cooling groove, setting a test voltage of 1.0kV to perform an online spark test on the insulating layer on the insulated wire core of the signal unit, and setting a test voltage of 3.5kV to perform an online spark test on the insulating layer on the insulated wire core of the power unit;
and step 3: the 4 power unit insulated wire cores are comprehensively cabled and coated with water-blocking sealant to form a power unit cable core, the cabling twisting direction is the right direction, and the twisting pitch is 135 +/-15 mm;
and 4, step 4: a water-blocking tape is wound outside the power unit cable core, and the covering rate is 20-25%;
and 5: drying the polyurethane sheath material at 50 +/-5 ℃ for 2 hours, injecting the polyurethane sheath material into a plastic single-screw extruder, and extruding a small polyurethane sheath I outside a water-blocking tape to obtain a power unit, wherein the thickness of the sheath is 1.8-2.0 mm; adopting an extrusion die in the plastic single-screw extruder, setting the temperature of a feed inlet of the extruder to be 135 +/-10 ℃, setting the temperature of a head of the extruder to be 180 +/-10 ℃, and setting the temperature to be increased in a stepped manner in a screw heating zone between the feed inlet of the extruder and the head of the extruder;
step 6: filling and twisting the two strands of signal unit insulated wire cores and aramid fibers in pairs and coating a water-blocking sealant to form an insulated wire core group, wherein the twisting direction is the left direction, and the twisting pitch is 45 +/-5 mm;
and 7: weaving a tinned round copper wire shielding layer outside the insulated wire core group and coating a water-blocking sealant, wherein the weaving pitch is 9.2 +/-3 mm;
and 8: 4 groups of shielding wire core groups are added with aramid fibers to fill and integrate cabling and coated with water-blocking sealant to form signal unit cable cores, the cabling direction is the right direction, and the stranding pitch is 110 +/-15 mm;
and step 9: a water-blocking tape is wound outside the signal unit cable core, and the covering rate is 20-25%;
step 10: weaving a tinned round copper wire shielding layer outside a water-blocking tape and coating a water-blocking sealant, wherein the weaving pitch is 34.5 +/-5 mm;
step 11: drying the polyurethane sheath material at 50 +/-5 ℃ for 2 hours, injecting the polyurethane sheath material into a plastic single-screw extruder, and extruding and coating a small polyurethane sheath II outside a tinned round copper wire shielding layer to obtain a signal unit, wherein the thickness of the sheath is 1.5-1.8 mm; adopting an extrusion die in the plastic single-screw extruder, setting the temperature of a feed inlet of the extruder to be 135 +/-10 ℃, setting the temperature of a head of the extruder to be 180 +/-10 ℃, and setting the temperature to be increased in a stepped manner in a screw heating zone between the feed inlet of the extruder and the head of the extruder;
step 12: drying the polyurethane sheath material at 50 +/-5 ℃ for 2 hours, injecting the polyurethane sheath material into a plastic single-screw extruder, and extruding and wrapping a polyurethane small sheath III outside a steel wire rope to obtain a bearing unit, wherein the thickness of the sheath is 2.5-3.0 mm; adopting an extrusion die in the plastic single-screw extruder, setting the temperature of a feed inlet of the extruder to be 135 +/-10 ℃, setting the temperature of a head of the extruder to be 180 +/-10 ℃, and setting the temperature to be increased in a stepped manner in a screw heating zone between the feed inlet of the extruder and the head of the extruder;
step 13: taking two groups of bearing units as centers, respectively arranging a group of power units and a group of signal units on two sides of the bearing units in parallel at an interval of 3.0-5.0 mm, wherein the special-shaped flat die sleeve is a special-shaped octagon, the upper long side and the lower long side of the special-shaped octagon are parallel and have the length of 48mm, the left short side and the right short side are parallel and have the length of 18mm, the length of four bevel edges is 19.2mm, 4 included angles between the bevel edge and the upper long side and the lower long side are 160 degrees, and 4 included angles between the bevel edge and;
step 14: drying the polyurethane sheath material at 50 +/-5 ℃ for 2 hours, and injecting the polyurethane sheath material into a plastic single-screw extruder to complete extrusion coating of a polyurethane outer sheath, so as to obtain the watertight load-bearing comprehensive special-shaped flat cable, wherein the thickness of the sheath is 3.0-10.0 mm; the plastic single-screw extruder adopts an extrusion type special-shaped flat die, the temperature of a feed inlet of the extruder is set to be 135 +/-10 ℃, the temperature of a head of the extruder is set to be 170 +/-10 ℃, and the temperature of a screw heating zone between the feed inlet of the extruder and the head of the extruder is set to be increased in a stepped manner, so that the beneficial effects of the invention are embodied in that:
1. excellent longitudinal water-tightness: the watertight load-bearing comprehensive special-shaped flat cable is characterized in that water-blocking sealant is coated on the conductor stranding layer, the optical fiber stranding layer, the cable core stranding layer and the braided shielding layer, so that the whole composite cable has good watertight performance, when the cable is broken due to external force, the watertight load-bearing comprehensive special-shaped flat cable bears 4.5MPa of longitudinal water pressure with the water depth of 450 meters, and can effectively prevent water from flowing longitudinally along the cable to damage equipment.
2. Excellent tensile properties: the watertight load-bearing comprehensive special-shaped flat cable adopts two steel wire ropes to extrude a small polyurethane sheath to form a load-bearing unit, so that the cable has excellent load-bearing tensile capacity, and the breaking-resistant tensile force of the cable can reach 200 kN.
3. Reliability of use: the use reliability of the cable is fully considered in the design process, the cable adopts two groups of bearing units as centers when being designed, a group of power units and a group of signal units are respectively arranged on two sides of the bearing units in parallel, the cable sheath is a deformed octagonal flat sheath, the cable bearing mode is optimized, the two groups of bearing unit sheaths are thickened, when the cable passes through a winding machine or a pulley block, the bearing units bear pressure, the power units and the signal units bear pressure, the damage risk of cable cores is reduced, and the use reliability of the cable is improved.
4. Good seawater corrosion resistance and wear resistance: the watertight load-bearing comprehensive special-shaped flat cable adopts polyurethane, has high strength, hydrolysis resistance, oil resistance, high resilience and good low-temperature performance, and is generally suitable for products in contact with water. The material has high tensile strength, flexibility, toughness, elasticity and good low temperature resistance, and simultaneously has salt spray resistance, mould resistance and seawater corrosion resistance.
Drawings
FIG. 1 is a schematic structural diagram of the present invention.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
Referring to fig. 1, the structure of the watertight load-bearing comprehensive special-shaped flat cable channel of the embodiment is as follows: a plurality of tinned round copper wires are stranded into a conductor 1 and coated with water-blocking sealant, the conductor 1 is externally extruded with an irradiation crosslinked polyethylene insulating layer to form a power unit insulating wire core, and the conductor 1-1 is externally extruded with a low-density polyethylene insulating layer 3 to form a signal unit insulating wire core.
The four power unit insulated wire cores are comprehensively cabled and coated with water-blocking sealant to form a power unit cable core, a water-blocking tape isolating layer 4 is arranged outside the power unit cable core, and a small polyurethane sheath I5 is extruded outside the isolating layer 4 to form a power unit; 6 pairs of two strands of signal unit insulated wire cores and aramid fibers are filled and coated with water-blocking sealant to form an insulated wire core group, tinned copper wires 7 are woven outside the insulated wire core group and coated with the water-blocking sealant to form a shielded wire core group, aramid fibers are added to the four shielded wire core groups to fill 6-1, comprehensive cabling is carried out, water-blocking sealant is coated to form a signal unit cable core, a water-blocking tape 4-1 is arranged outside the signal unit cable core, tinned round copper wires are woven to form a shielded layer 7-1, and a small polyurethane sheath II 5-1 is extruded outside the shielded layer 7-1 to form a signal unit; two steel wire ropes 8 extrude out of a polyurethane small sheath III 5-2 to form a bearing unit.
Two groups of bearing units are used as centers, one group of power units and one group of signal units are respectively arranged on two sides of the bearing units in parallel, and finally polyurethane is extruded to be used as an outer sheath 5-3.
In the specific implementation, the stranded tinned copper wire stranded conductor (1) is firstly regularly stranded according to a 1+7 arrangement mode and coated with water-blocking sealant to obtain 7 stranded wire core elements, the stranding direction is the right direction, then 7 groups of 7 stranded wire core element conductors are regularly stranded according to a 1+7 arrangement mode and coated with water-blocking sealant to obtain a power unit core conductor, and the stranding direction is the left direction; the signal unit is made of irradiation cross-linked polyethylene (2) insulating material, and the insulating thickness is 0.6-0.7 mm; a plurality of strands of tinned copper wire stranded conductors (1-1) are regularly stranded according to a 1+7 arrangement mode and coated with water-blocking sealant to obtain signal unit conductors, and the stranding direction is the left direction; the signal unit is made of low-density polyethylene (3) insulating material, and the insulating thickness is 0.4-0.5 mm; the four power unit insulated wire cores are comprehensively cabled and coated with water-blocking sealant to form a power unit cable core, a water-blocking belting (4) isolation layer is arranged outside the power unit cable core, polyurethane (5) is extruded outside the isolation layer, a small sheath II is formed, and the thickness of the sheath is 1.8-2.0 mm; two strands of signal unit insulated wire cores and aramid fiber wire filling (6) are twisted in pairs and coated with water-blocking sealant to form an insulated wire core group, tinned copper wires (7) are woven outside the insulated wire core group and coated with the water-blocking sealant to form a shielded wire core group, aramid fiber wire filling (6-1) is added into four shielded wire core groups to be comprehensively cabled and coated with the water-blocking sealant to form a signal unit cable core, a water-blocking tape (4-1) isolating layer is arranged outside the signal unit cable core, a tinned round copper wire (7-1) is woven to form a shielding layer, polyurethane (5-1) small sheaths II are extruded outside the shielding layer to form a signal unit, and the sheath thickness is 1.5-1.8 mm; two steel wire ropes (8) extrude polyurethane (5-2) and small sheaths III to form a bearing unit, wherein the thickness of the sheaths is 2.5-3.0 mm; two groups of bearing units are used as centers, one group of power units and one group of signal units are respectively arranged on two sides of the bearing units in parallel, finally polyurethane (5-3) is extruded to be used as an outer sheath, the arrangement interval of each unit is 3.0-5.0 mm, and the thickness of the outer sheath is 3.0-10.0 mm.
The manufacturing process of the watertight load-bearing comprehensive special-shaped flat cable in the embodiment is carried out according to the following steps:
step 1: the method comprises the following steps that 49 strands of tinned round copper wires are adopted for power unit wire cores, firstly, regular stranding is carried out according to a 1+7 arrangement mode, water-blocking sealant is coated on the tinned round copper wires to obtain 7 strands of twisted wire core components, the stranding direction is the right direction, the stranding pitch is 13 +/-1 mm, then 7 groups of 7 strands of twisted wire core component conductors are regularly stranded according to a 1+7 arrangement mode, water-blocking sealant is coated on the conductors to obtain power unit conductors, the stranding direction is the left direction, and the stranding pitch is 39 +/-3 mm; the signal unit wire core is made of 7 strands of tinned round copper wires, is normally stranded according to a 1+7 arrangement mode, and is coated with a water-blocking sealant to obtain a signal unit conductor, wherein the stranding direction is the left direction, and the stranding pitch is 11 +/-1 mm;
step 2: drying the irradiation crosslinked polyethylene material at 40 +/-5 ℃ for 2 hours, and injecting the dried irradiation crosslinked polyethylene material into a plastic single-screw extruder to complete extrusion coating of an irradiation crosslinked polyethylene insulating layer, so as to prepare an insulating wire core of the power unit, wherein the insulating thickness of the insulating wire core is 0.6-0.7 mm; drying the low-density polyethylene material at 50 +/-5 ℃ for 2 hours, and injecting the dried low-density polyethylene material into a plastic single-screw extruder to complete extrusion coating of a low-density polyethylene insulating layer to obtain a signal unit insulating wire core, wherein the insulating thickness of the signal unit insulating wire core is 0.4-0.5 mm; adopting an extrusion die in the plastic single-screw extruder, setting the temperature of a feed inlet of the extruder to be 150 +/-10 ℃, setting the temperature of a head of the extruder to be 200 +/-10 ℃, and setting the temperature to be increased in a stepped manner in a screw heating zone between the feed inlet of the extruder and the head of the extruder; aiming at the outgoing line of the insulated wire core from the cooling groove, 1.0kV of test voltage is set to perform online spark test on the insulating layer on the insulated wire core of the signal unit, and 3.5kV of test voltage is set to perform online spark test on the insulating layer on the insulated wire core of the power unit.
And step 3: and 4 power unit insulated wire cores are comprehensively cabled and coated with water-blocking sealant to form a power unit cable core, the cabling direction is the right direction, and the stranding pitch is 135 +/-15 mm.
And 4, step 4: and a water-blocking tape is wound outside the power unit cable core, and the covering rate is 20-25%.
And 5: drying the polyurethane sheath material at 50 +/-5 ℃ for 2 hours, injecting the polyurethane sheath material into a plastic single-screw extruder, and extruding a small polyurethane sheath I outside a water-blocking tape to obtain a power unit, wherein the thickness of the sheath is 1.8-2.0 mm; an extrusion die is adopted in the plastic single-screw extruder, the temperature of a feed inlet of the extruder is set to be 135 +/-10 ℃, the temperature of a head of the extruder is set to be 180 +/-10 ℃, and the temperature of a screw heating zone between the feed inlet of the extruder and the head of the extruder is set to be increased in a stepped mode.
Step 6: filling and twisting the two strands of signal unit insulated wire cores and aramid fibers in pairs and coating a water-blocking sealant to form an insulated wire core group, wherein the twisting direction is the left direction, and the twisting pitch is 45 +/-5 mm;
and 7: and weaving a tinned round copper wire shielding layer outside the insulated wire core group and coating a water-blocking sealant, wherein the weaving pitch is 9.2 +/-3 mm.
And 8: and 4 groups of shielding wire core groups are added with aramid fibers to fill and synthesize cabling and coated with water-blocking sealant to form a signal unit cable core, the cabling direction is the right direction, and the stranding pitch is 110 +/-15 mm.
And step 9: and a water-blocking tape is wound outside the signal unit cable core, and the covering rate is 20-25%.
Step 10: and weaving a tinned round copper wire shielding layer outside the water-blocking tape and coating water-blocking sealant, wherein the weaving pitch is 34.5 +/-5 mm.
Step 11: drying the polyurethane sheath material at 50 +/-5 ℃ for 2 hours, injecting the polyurethane sheath material into a plastic single-screw extruder, and extruding and coating a small polyurethane sheath II outside a tinned round copper wire shielding layer to obtain a signal unit, wherein the thickness of the sheath is 1.5-1.8 mm; an extrusion die is adopted in the plastic single-screw extruder, the temperature of a feed inlet of the extruder is set to be 135 +/-10 ℃, the temperature of a head of the extruder is set to be 180 +/-10 ℃, and the temperature of a screw heating zone between the feed inlet of the extruder and the head of the extruder is set to be increased in a stepped mode.
Step 12: drying the polyurethane sheath material at 50 +/-5 ℃ for 2 hours, injecting the polyurethane sheath material into a plastic single-screw extruder, and extruding and wrapping a polyurethane small sheath III outside a steel wire rope to obtain a bearing unit, wherein the thickness of the sheath is 2.5-3.0 mm; an extrusion die is adopted in the plastic single-screw extruder, the temperature of a feed inlet of the extruder is set to be 135 +/-10 ℃, the temperature of a head of the extruder is set to be 180 +/-10 ℃, and the temperature of a screw heating zone between the feed inlet of the extruder and the head of the extruder is set to be increased in a stepped mode.
Step 13: two sets of bearing units are used as centers, a set of power unit and a set of signal unit are respectively arranged on two sides of the bearing units in parallel, the arrangement interval of the bearing units is 3.0-5.0 mm, the special-shaped flat die sleeve is a special-shaped octagon, the upper long edge and the lower long edge of the special-shaped flat die sleeve are parallel and have the length of 48mm, the left short edge and the right short edge of the special-shaped flat die sleeve are parallel and have the length of 18mm, the length of four bevel edges is 19.2mm, 4 included angles of the bevel edge and the upper long edge and the.
Step 14: drying the polyurethane sheath material at 50 +/-5 ℃ for 2 hours, and injecting the polyurethane sheath material into a plastic single-screw extruder to complete extrusion coating of a polyurethane outer sheath, so as to obtain the watertight load-bearing comprehensive special-shaped flat cable, wherein the thickness of the sheath is 3.0-10.0 mm; an extrusion type special-shaped flat die is adopted in the plastic single-screw extruder, the temperature of a feed inlet of the extruder is set to be 135 +/-10 ℃, the temperature of a head of the extruder is set to be 170 +/-10 ℃, and the temperature of a screw heating zone between the feed inlet of the extruder and the head of the extruder is set to be increased in a stepped mode.
The structure and performance indexes of the watertight load-bearing comprehensive special-shaped flat cable are listed in table 1:
TABLE 1
Figure RE-DEST_PATH_IMAGE001
According to the watertight load-bearing comprehensive special-shaped flat cable, as can be seen from the table 1, the watertight load-bearing comprehensive special-shaped flat cable has excellent electrical performance and mechanical performance, and simultaneously has good water tightness and excellent tensile performance.
Although particular embodiments of the invention have been described and illustrated in detail, it should be understood that various equivalent changes and modifications could be made to the above-described embodiments in accordance with the spirit of the invention, and the resulting functional effects would still fall within the scope of the invention.

Claims (6)

1. The utility model provides a special-shaped flat cable is synthesized in watertight bearing, includes the conductor, and its special type lies in:
the device also comprises a bearing unit, a power unit and a signal unit;
the cable takes the bearing unit as the center, the power unit and the signal unit are respectively arranged on two sides of the bearing unit in parallel, and polyurethane is extruded outside the bearing unit, the power unit and the signal unit to form a polyurethane outer sheath;
the conductor is externally extruded with a low-density polyethylene insulating layer to form a signal unit insulating wire core; the two strands of signal unit insulated wire cores and aramid fibers are filled and twisted in pairs and coated with water-blocking sealant to form an insulated wire core group;
the insulated wire core group is externally woven with tinned copper wires and coated with water-blocking sealant to form a shielded wire core group, and the four shielded wire core groups are added with aramid fibers to be filled and comprehensively formed into a cable and coated with water-blocking sealant to form a signal unit cable core;
a water-blocking wrapping tape isolating layer is arranged outside the signal unit cable core, a tinned round copper wire braided shielding layer is arranged outside the shielding layer, and a small polyurethane sheath II is extruded outside the shielding layer to form a signal unit;
the conductor is externally extruded with an irradiation crosslinked polyethylene insulating layer to form a power unit insulating wire core, and four strands of power unit insulating wire cores are comprehensively cabled and coated with water-blocking sealant to form a power unit cable core;
a water-blocking wrapping tape isolating layer is arranged outside the power unit cable core, and a small polyurethane sheath I is extruded outside the isolating layer to form a power unit;
and extruding polyurethane small sheaths III by the two steel wire ropes to form bearing unit glue.
2. The watertight load-bearing comprehensive special-shaped flat cable according to claim 1, which is characterized in that: a plurality of tinned round copper wires are stranded into a conductor and coated with a water-blocking sealant.
3. The watertight load-bearing complex shaped flat cable as claimed in claim 1, wherein said cable sheath cross-section is rectangular with four corners removed, i.e. a cross-section of a flat sheath in the shape of an irregular octagon.
4. The watertight load-bearing complex shaped flat cable as claimed in claim 1, wherein said signal unit and power unit are both longitudinal watertight structures.
5. The watertight load-bearing comprehensive special-shaped flat cable according to claim 1, wherein the insulation thickness of the irradiation crosslinked polyethylene insulation layer is 0.8-1.2 mm; the insulation thickness of the low-density polyethylene insulation layer is 0.4-0.8 mm; the thickness of the polyurethane sheath is 1.5-10.0 mm.
6. A production method of a watertight load-bearing comprehensive special-shaped flat cable is characterized by comprising the following steps:
step 1: the method comprises the following steps that 49 strands of tinned round copper wires are adopted for power unit wire cores, firstly, regular stranding is carried out according to a 1+7 arrangement mode, water-blocking sealant is coated on the tinned round copper wires to obtain 7 strands of twisted wire core components, the stranding direction is the right direction, the stranding pitch is 13 +/-1 mm, then 7 groups of 7 strands of twisted wire core component conductors are regularly stranded according to a 1+7 arrangement mode, water-blocking sealant is coated on the conductors to obtain power unit conductors, the stranding direction is the left direction, and the stranding pitch is 39 +/-3 mm;
the signal unit wire core is made of 7 strands of tinned round copper wires, is normally stranded according to a 1+7 arrangement mode, and is coated with a water-blocking sealant to obtain a signal unit conductor, wherein the stranding direction is the left direction, and the stranding pitch is 11 +/-1 mm;
step 2: drying the irradiation crosslinked polyethylene material at 40 +/-5 ℃ for 2 hours, and injecting the dried irradiation crosslinked polyethylene material into a plastic single-screw extruder to complete extrusion coating of an irradiation crosslinked polyethylene insulating layer, so as to prepare an insulating wire core of the power unit, wherein the insulating thickness of the insulating wire core is 0.6-0.7 mm; drying the low-density polyethylene material at 50 +/-5 ℃ for 2 hours, and injecting the dried low-density polyethylene material into a plastic single-screw extruder to complete extrusion coating of a low-density polyethylene insulating layer to obtain a signal unit insulating wire core, wherein the insulating thickness of the signal unit insulating wire core is 0.4-0.5 mm;
adopting an extrusion die in the plastic single-screw extruder, setting the temperature of a feed inlet of the extruder to be 150 +/-10 ℃, setting the temperature of a head of the extruder to be 200 +/-10 ℃, and setting the temperature to be increased in a stepped manner in a screw heating zone between the feed inlet of the extruder and the head of the extruder; aiming at the outgoing line of the insulated wire core from the cooling groove, setting a test voltage of 1.0kV to perform an online spark test on the insulating layer on the insulated wire core of the signal unit, and setting a test voltage of 3.5kV to perform an online spark test on the insulating layer on the insulated wire core of the power unit;
and step 3: the 4 power unit insulated wire cores are comprehensively cabled and coated with water-blocking sealant to form a power unit cable core, the cabling twisting direction is the right direction, and the twisting pitch is 135 +/-15 mm;
and 4, step 4: a water-blocking tape is wound outside the power unit cable core, and the covering rate is 20-25%;
and 5: drying the polyurethane sheath material at 50 +/-5 ℃ for 2 hours, injecting the polyurethane sheath material into a plastic single-screw extruder, and extruding a small polyurethane sheath I outside a water-blocking tape to obtain a power unit, wherein the thickness of the sheath is 1.8-2.0 mm; adopting an extrusion die in the plastic single-screw extruder, setting the temperature of a feed inlet of the extruder to be 135 +/-10 ℃, setting the temperature of a head of the extruder to be 180 +/-10 ℃, and setting the temperature to be increased in a stepped manner in a screw heating zone between the feed inlet of the extruder and the head of the extruder;
step 6: filling and twisting the two strands of signal unit insulated wire cores and aramid fibers in pairs and coating a water-blocking sealant to form an insulated wire core group, wherein the twisting direction is the left direction, and the twisting pitch is 45 +/-5 mm;
and 7: weaving a tinned round copper wire shielding layer outside the insulated wire core group and coating a water-blocking sealant, wherein the weaving pitch is 9.2 +/-3 mm;
and 8: 4 groups of shielding wire core groups are added with aramid fibers to fill and integrate cabling and coated with water-blocking sealant to form signal unit cable cores, the cabling direction is the right direction, and the stranding pitch is 110 +/-15 mm;
and step 9: a water-blocking tape is wound outside the signal unit cable core, and the covering rate is 20-25%;
step 10: weaving a tinned round copper wire shielding layer outside a water-blocking tape and coating a water-blocking sealant, wherein the weaving pitch is 34.5 +/-5 mm;
step 11: drying the polyurethane sheath material at 50 +/-5 ℃ for 2 hours, injecting the polyurethane sheath material into a plastic single-screw extruder, and extruding and coating a small polyurethane sheath II outside a tinned round copper wire shielding layer to obtain a signal unit, wherein the thickness of the sheath is 1.5-1.8 mm; adopting an extrusion die in the plastic single-screw extruder, setting the temperature of a feed inlet of the extruder to be 135 +/-10 ℃, setting the temperature of a head of the extruder to be 180 +/-10 ℃, and setting the temperature to be increased in a stepped manner in a screw heating zone between the feed inlet of the extruder and the head of the extruder;
step 12: drying the polyurethane sheath material at 50 +/-5 ℃ for 2 hours, injecting the polyurethane sheath material into a plastic single-screw extruder, and extruding and wrapping a polyurethane small sheath III outside a steel wire rope to obtain a bearing unit, wherein the thickness of the sheath is 2.5-3.0 mm; adopting an extrusion die in the plastic single-screw extruder, setting the temperature of a feed inlet of the extruder to be 135 +/-10 ℃, setting the temperature of a head of the extruder to be 180 +/-10 ℃, and setting the temperature to be increased in a stepped manner in a screw heating zone between the feed inlet of the extruder and the head of the extruder;
step 13: taking two groups of bearing units as centers, respectively arranging a group of power units and a group of signal units on two sides of the bearing units in parallel at an interval of 3.0-5.0 mm, wherein the special-shaped flat die sleeve is a special-shaped octagon, the upper long side and the lower long side of the special-shaped octagon are parallel and have the length of 48mm, the left short side and the right short side are parallel and have the length of 18mm, the length of four bevel edges is 19.2mm, 4 included angles between the bevel edge and the upper long side and the lower long side are 160 degrees, and 4 included angles between the bevel edge and;
step 14: drying the polyurethane sheath material at 50 +/-5 ℃ for 2 hours, and injecting the polyurethane sheath material into a plastic single-screw extruder to complete extrusion coating of a polyurethane outer sheath, so as to obtain the watertight load-bearing comprehensive special-shaped flat cable, wherein the thickness of the sheath is 3.0-10.0 mm; an extrusion type special-shaped flat die is adopted in the plastic single-screw extruder, the temperature of a feed inlet of the extruder is set to be 135 +/-10 ℃, the temperature of a head of the extruder is set to be 170 +/-10 ℃, and the temperature of a screw heating zone between the feed inlet of the extruder and the head of the extruder is set to be increased in a stepped mode.
CN201911334942.2A 2019-12-23 2019-12-23 Watertight load-bearing comprehensive special-shaped flat cable and production method thereof Withdrawn CN111009348A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114167558A (en) * 2021-10-19 2022-03-11 富通集团(嘉善)通信技术有限公司 Mining optical cable and assembly thereof

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114167558A (en) * 2021-10-19 2022-03-11 富通集团(嘉善)通信技术有限公司 Mining optical cable and assembly thereof
CN114167558B (en) * 2021-10-19 2023-09-26 富通集团(嘉善)通信技术有限公司 Mining optical cable and assembly thereof

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