CN112185614A - Double-layer sheath spiral cable and manufacturing process thereof - Google Patents

Abstract

The embodiment of the application provides a double-layer sheath spiral cable and a manufacturing process thereof, and relates to the field of special cables. Double-deck sheath spiral cable includes the cable core that forms by a plurality of sinle silk transposition, and the cable core outward in proper order the cladding has band layer, inner sheath and oversheath, and the material of inner sheath is polyester type polyurethane, and the material of oversheath is polyether type polyurethane. The manufacturing process of the double-layer sheath spiral cable is to twist a plurality of wire cores to form a cable core, and a wrapping layer is coated outside the cable core; adopting polyester polyurethane, and coating the wrapping tape layer to form an inner sheath; adopting polyether polyurethane, and coating the outer sheath outside the inner sheath to form an outer sheath to obtain a linear cable; and (5) spirally rolling and forming the cable. The double-layer sheath spiral cable is low in cost, high in strength, good in bending performance and good in roundness, and can meet the requirement of long-term stable use in frequent stretching and vibration working conditions.

Description

Double-layer sheath spiral cable and manufacturing process thereof

Technical Field

The application relates to the field of special cables, in particular to a double-layer sheath spiral cable and a manufacturing process thereof.

Background

A spiral cable, also called a spring cable, is generally a spiral cable formed by a winding process of a straight cable formed by stranding a plurality of insulated wire cores. The spiral cable is a device connecting wire which works by utilizing the spiral scalability of the cable, is used for providing the connection and transmission of power and signals of the movable device in the process of movement operation, and can quickly rebound in a short time.

Traditional spiral cable adopts individual layer polyether polyurethane preparation sheath, and the tensile strength of sheath is not enough, and in long-term use, because frequent drawing, vibrations, cable elasticity can reduce, can't effectively protect the sinle silk, leads to the cable life-span short, has the potential safety hazard. Moreover, the sheath is extruded in a single layer, so that the roundness of the cable is poor; the cost of the cable is high due to the high cost of the polyether polyurethane.

Disclosure of Invention

An object of the embodiment of the application is to provide a double-layer sheath spiral cable and a manufacturing process thereof, wherein the double-layer sheath spiral cable is low in cost, high in strength, good in bending performance and good in roundness, and can meet the requirement of long-term stable use in frequent stretching and vibration working conditions.

In a first aspect, the embodiment of the application provides a double-layer sheath spiral cable, which comprises a cable core formed by twisting a plurality of cable cores, wherein the cable core is sequentially wrapped with a belting layer, an inner sheath and an outer sheath, the inner sheath is made of polyester polyurethane, and the outer sheath is made of polyether polyurethane.

In the implementation process, the inventor discovers that compared with polyether polyurethane, polyester polyurethane has higher tensile strength and tearing strength, better wear resistance and lower price, but the polyester polyurethane is not resistant to hydrolysis. To the characteristic of above two kinds of polyurethane materials, this application adopts different polyurethane materials to make double-deck sheath, has guaranteed spiral cable circulation tensile properties (bending property promptly), and spiral cable is whole to have elasticity, can stretch to certain extent along length direction to can resume to former heliciform. The inner sheath of the inner layer is made of polyester polyurethane, the outer sheath of the outer layer is made of polyether polyurethane, the cost is low, the tensile strength and the tearing strength are high, the core wire is well protected, the bending performance of the cable with the double-layer sheath is good, the roundness is good, the requirement for long-term stable use in frequent stretching and vibration working conditions can be met, and the cable is particularly suitable for being used as a special cable, such as an ABS (acrylonitrile butadiene styrene) cable for a trailer, and the service life of the cable is long.

In one possible implementation manner, the material of the inner sheath is a thermoplastic polyester type polyurethane elastomer material; the outer sheath is made of thermoplastic polyether type polyurethane elastomer material.

In the implementation process, the inner sheath is made of a high-strength and high-elongation polyester polyurethane elastomer (TPU) material, so that the cyclic tensile property and reliability of the spiral cable are ensured; the outer sheath is made of a hydrolysis-resistant and low-temperature-resistant polyether polyurethane elastomer (TPU) material, so that the cyclic tensile property and durability of the spiral cable are ensured; the double-layer sheath formed by the two polyurethane materials can ensure that the spiral cable is high in strength and good in bending performance, can effectively protect the core wire, and ensures the service life of the spiral cable.

In one possible implementation mode, the wire core comprises a conductor and an insulating layer wrapped outside the conductor; optionally, the conductor is formed by twisting a plurality of copper wires together, and the ratio of the twist pitch diameter of the strands is not more than 20 times; optionally, the insulating layer is made of PVC.

In the implementation process, a plurality of ultra-soft copper wires are combined together by adopting a wire bundling and stranding process, and the ratio of the bundle-stranding pitch diameter is strictly controlled within 20 times, so that the formed conductor can be ensured to have higher flexible bending performance; and the high-wear-resistance PVC is adopted, so that the surface of the conductor is conveniently wrapped to form an insulating layer, and the protection effect on the conductor is good.

In one possible implementation, all the wire cores are arranged into at least two layers, and the twisting directions of the wire cores of each layer are the same; and/or the stranding pitch diameter ratio of the wire core is 4-15 times.

In the implementation process, the insulated wire cores are uniformly stranded together in a layered mode, the stranding directions of the wire cores of all layers are in the same direction, the stranding pitch diameter ratio is 4-15 times, a spiral cable is convenient to form, and the bending performance of the spiral cable is guaranteed.

In one possible implementation manner, the material of the belting layer is polyester plastic, paper or non-woven fabric; and/or the belting layer is formed by a lapping mode, and the coverage rate of the belting layer is 10-80%.

In the implementation process, a tape wrapping process is adopted, the tape is uniformly wrapped on the cable, the coverage rate of the tape is 10% -80%, and the compactness and the roundness of the twisted wire cores are guaranteed.

In a possible realization mode, the total thickness of the inner sheath and the outer sheath is 1.5-2 mm.

In the implementation process, the total thickness of the inner sheath and the outer sheath is 1.5-2 mm, and the strength and the bending performance of the formed spiral cable can be guaranteed. If the total thickness is too large, the bending performance of the spiral cable cannot be ensured, the spiral cable is difficult to process into a spiral cable, or the spiral cable is difficult to stretch and restore; if the total thickness is too small, the strength of the spiral cable cannot be secured.

In a second aspect, the present application provides a manufacturing process of the double-layer sheathed spiral cable provided in the first aspect, which includes the following steps:

stranding a plurality of wire cores to form a cable core, and covering the cable core to form a belting layer;

adopting polyester polyurethane, and coating the wrapping tape layer to form an inner sheath;

adopting polyether polyurethane, and coating the outer sheath outside the inner sheath to form an outer sheath to obtain a linear cable;

and (5) spirally rolling and forming the cable.

In the implementation process, the cable core is provided with the belting layer, the inner sheath of the polyester polyurethane and the outer sheath of the polyether polyurethane are sequentially formed outside, the roundness of the cable is good, the formed spiral cable is low in cost and high in strength, and the requirement for long-term stable use in frequent stretching and vibration working conditions can be met.

In a possible implementation manner, the wrapping forming method of the wrapping layer is as follows: and a tape wrapping process is adopted, a tape is uniformly wrapped on the cable core to form a tape layer, and the coverage rate of the tape is 10% -80%.

In the implementation process, a band wrapping process is adopted, the band is uniformly wrapped on the cable core, the coverage rate of the band is 10% -80%, the wrapping process is performed to enable the band layer to be tight and flat and not to wrinkle or fold, and the compactness of the twisted cable core is ensured.

In one possible implementation manner, the coating forming method of the inner sheath is as follows: extruding and molding outside the wrapping layer through an extruder, wherein the temperature of each section of the extruder is 180-220 ℃, and the temperature of a head die of the extruder is 180-220 ℃;

and/or the coating forming method of the outer sheath comprises the following steps: and extruding and molding outside the wrapping layer by an extruder, wherein the temperature of each section of the extruder is 180-220 ℃, and the temperature of a head die of the extruder is 180-220 ℃.

In the implementation process, the inner sheath and the outer sheath are formed by adopting a double-layer extrusion process, so that the overall elasticity and strength of the sheath are ensured.

In one possible implementation manner, the method for forming the spiral roll is as follows: winding the cable on a winding rod to form a spiral shape, then baking the cable for 60-100 min at 130-140 ℃, and air cooling; the diameter of the winding rod is 3-4 times of the outer diameter of the cable.

In the implementation process, the cable is coiled into a spiral shape, and then is subjected to heat treatment and cold treatment to form the cable into the spiral cable, and meanwhile, the roundness, the strength and the bending performance of the cable are kept.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are required to be used in the embodiments of the present application will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present application and therefore should not be considered as limiting the scope, and that those skilled in the art can also obtain other related drawings based on the drawings without inventive efforts.

Fig. 1 is a schematic structural diagram of a double-jacketed spiral cable according to an embodiment of the present disclosure;

FIG. 2 is a cross-sectional view of a double-jacketed helical cable provided in accordance with a first embodiment of the present application;

FIG. 3 is a linear relationship graph of the thickness of the inner jacket and the number of bends of the corresponding cable;

FIG. 4 is a linear plot of the thickness of the inner jacket versus the percent cost reduction of the corresponding cable;

fig. 5 is a linear relationship graph of the thickness of the inner jacket with the number of bends and the number of pull-ups of the corresponding cable.

Icon: 100-a spiral cable; 110-a conductor; 120-an insulating layer; 130-a belting layer; 140-an inner sheath; 150-outer sheath.

Detailed Description

The technical solutions in the embodiments of the present application will be described below with reference to the drawings in the embodiments of the present application.

In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are some embodiments of the present application, but not all embodiments. The components of the embodiments of the present application, generally described and illustrated in the figures herein, can be arranged and designed in a wide variety of different configurations.

Thus, the following detailed description of the embodiments of the present application, as presented in the figures, is not intended to limit the scope of the claimed application, but is merely representative of selected embodiments of the application. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.

It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined and explained in subsequent figures.

In the description of the present application, it should be noted that the terms "center", "upper", "inner", "outer", and the like indicate orientations or positional relationships based on orientations or positional relationships shown in the drawings or orientations or positional relationships conventionally found in use of products of the application, and are used only for convenience in describing the present application and for simplification of description, and do not indicate or imply that the referred devices or elements must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present application.

In the description of the present application, it is also to be noted that, unless otherwise explicitly specified or limited, the term "disposed" is to be understood broadly, for example, as being fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present application can be understood in a specific case by those of ordinary skill in the art.

First embodiment

Referring to fig. 1 and 2, the spiral cable 100 with a double-layer sheath provided in this embodiment is spiral, and includes a cable core formed by twisting a plurality of cable cores, and the cable core is sequentially covered with a belting layer 130, an inner sheath 140 and an outer sheath 150. The inner sheath 140 and the outer sheath 150 are both made of thermoplastic polyurethane elastomer materials, specifically, the inner sheath 140 is made of polyester polyurethane, and the outer sheath 150 is made of polyether polyurethane.

This application does not do the special limitation to the figure of sinle silk, need can the transposition together, and can bend into the heliciform can, in this embodiment, the figure of sinle silk is 7, 7 core structures promptly. The arrangement mode of the wire cores is not particularly limited in the application, and the wire cores are generally arranged in layers around a central line, and can be arranged in one layer or two or more layers; the stranding pitch diameter ratio of the wire core is generally 4-15 times, for example, the stranding pitch diameter ratio is 4 times, 6 times, 8 times, 10 times, 12 times or 15 times.

In order to ensure that the spiral cable 100 can be formed and meet the requirement of long-term stable use in frequent stretching and vibration conditions, the inner sheath 140 may be made of a thermoplastic polyester type polyurethane elastomer (TPU) material, and further may be made of a high-strength and high-elongation polyester type polyurethane elastomer (TPU) material, such as Basf TDS-S85A-zn. The outer sheath 150 may be made of a thermoplastic polyether urethane elastomer (TPU), and further may be made of a hydrolysis-resistant and low-temperature-resistant polyether urethane elastomer (TPU), such as 1185a 10HFFR 000.

In this embodiment, the core includes a conductor 110 and an insulating layer 120 covering the conductor 110. Optionally, the conductor 110 is formed by twisting a plurality of bundles (strands) of ultra-soft copper wires, for example, the conductor 110 is formed by twisting ultra-fine category 6 ultra-soft copper wires conforming to IEC 60228 and 2004; the conductor 110 typically has a bundle lay ratio of no more than 20, for example 5, 10, 15 or 20. Optionally, the insulating layer 120 is made of high wear-resistant PVC, such as Cabopol FHI-9901-91A.

Under general conditions, the outer diameter of the wire core is generally 2.0-4.0 mm, and the outer diameter of the cable core is generally 6.0-13.0 mm.

In this embodiment, the material of the wrapping layer 130 may be polyester plastic, paper or non-woven fabric; the wrapping layer 130 is formed by wrapping, and has a coverage of 10% to 80%, for example, 10%, 20%, 30%, 40%, 50%, 60%, 70%, or 80% for the cable core.

Generally, the thickness of the wrapping layer 130 is generally 0.03 to 0.20 mm.

In the embodiment, the total thickness of the inner sheath 140 and the outer sheath 150 is generally 1 to 2.5mm, wherein the thickness of the inner sheath 140 is generally 0.5 to 1.5mm, and the thickness of the outer sheath 150 is generally 0.5 to 1 mm. The inner sheath 140 and the outer sheath 150 having such a thickness form the spiral cable 100 not only at a low cost but also having a good strength and bending property.

In addition, the embodiment of the present application provides a manufacturing process of the above-mentioned double-layer sheathed spiral cable 100, which includes the following steps:

step (1), 7 cable cores are stranded to form a cable core, and the specific method can be as follows:

the ultra-fine category 6 ultra-soft bundles are stranded together to form the conductor 110 by adopting a copper wire bundle wire and stranding process, and the bundle stranding pitch ratio is strictly controlled within 20 times, so that the conductor 110 is ensured to have higher flexible bending performance; adopting an extrusion process, heating, plasticizing, melting and uniformly extruding the insulating material on the conductor 110 by an extruder to form an insulating layer 120, and obtaining a wire core; a stranding and cabling process is adopted, 7 wire cores are arranged in a layer and stranded together through a cabling machine, and the stranding pitch-diameter ratio is 4-15 times, so that a cable core is formed.

Step (2), forming a belting layer 130 outside the cable core in a coating manner, wherein the specific method can be as follows:

and a tape wrapping process is adopted, the tape head is wrapped to uniformly wrap the tape on the cable core to form a tape wrapping layer 130, the coverage rate of the tape is 10% -80%, and the wrapping layer is tight and flat and cannot be wrinkled or folded.

Step (3), forming the inner sheath 140 by coating the belting layer 130 with polyester polyurethane, which comprises the following specific steps:

the polyester TPU elastomer material is extruded and molded outside the belting layer 130 through an extruder, the temperature of each section of the extruder is 180-220 ℃, and the temperature of a head die of the extruder is 180-220 ℃.

Step (4), adopting polyether polyurethane, and coating the outer sheath 150 outside the inner sheath 140 to obtain the linear cable, wherein the specific method comprises the following steps:

the polyether type TPU elastomer material is extruded and molded outside the belting layer 130 through an extruder, the temperature of each section of the extruder is 180-220 ℃, and the temperature of a head die of the extruder is 180-220 ℃.

Step (5), spirally rolling and molding the cable, wherein the specific method comprises the following steps:

and (2) winding the cable on a winding rod to form a spiral shape, wherein the diameter of the winding rod is 3-4 times of the outer diameter of the cable, then baking the cable through a high-temperature box at the baking temperature of 130-140 ℃ for 60-100 min, air cooling, cooling the shaped cable through a fan for 4-5 hours generally, and obtaining the spiral cable 100.

The effect of the thickness of the inner sheath 140 and the outer sheath 150 on the bending performance of the cable is examined by experiments below.

According to the above manufacturing process, the total thickness of the inner sheath 140 and the outer sheath 150 is controlled to be 1.80mm, different spiral cables 100 are prepared by adjusting the respective thicknesses of the inner sheath 140 and the outer sheath 150 to be different, and the maximum number of times of cyclic stretching of each spiral cable 100 is examined, with the results as shown in the following table 1:

TABLE 1 results corresponding to the number of cycles of stretching of the spiral cable 100 for the inner and outer sheaths 140, 150 of different thicknesses

Spiral cable	Thickness/mm of inner sheath	Thickness of outer sheath/mm	Number of cycles of stretching
				1	0	1.8	23405
2	0.2	1.6	23605
				3	0.4	1.4	23761
4	0.6	1.2	23908
				5	0.8	1.0	24004
6	1.0	0.8	24080
				7	1.2	0.6	24182
8	1.4	0.4	24280
				9	1.6	0.2	24320
10	1.8	0.0	24350

A line graph of the thickness of the inner sheath 140 versus the number of times of cyclic stretching of the corresponding spiral cable 100, i.e., fig. 3, is plotted according to table 1, and a line graph of the percentage reduction in the thickness of the inner sheath 140 versus the cost of the spiral cable 100 (here, the cost is only the sheath material cost) of the spiral cable 100 having a thickness of 0mm for the inner sheath 140 and a thickness of 1.8mm for the outer sheath 150, i.e., fig. 4, is plotted according to the thickness of the inner sheath 140 versus the corresponding spiral cable 100.

As can be seen from fig. 3, on the premise that the total thickness of the inner sheath 140 and the outer sheath 150 is constant, the larger the thickness of the inner sheath 140 is, the larger the number of times of the cyclic stretching of the spiral cable 100 is, which indicates that the polyester polyurethane can improve the bending performance of the spiral cable 100 compared with the polyether polyurethane made into the sheath.

As can be seen from fig. 4, on the premise that the total thickness of the inner sheath 140 and the outer sheath 150 is constant, the larger the thickness of the inner sheath 140 is, the lower the cost of the spiral cable 100 is, which means that the polyester polyurethane can reduce the cost of the spiral cable 100 compared with the sheath made of polyether polyurethane.

In addition, the fray resistance (i.e., the abrasion resistance of outer jacket 150) of each of the spiral cables 100 was separately examined by a fray resistance test, which measures the length of outer jacket 150 frayed on sandpaper, according to test standard "ISO 145722011-10," and the results are shown in table 2. As can be seen from the inspection results, on the premise that the total thickness of the inner sheath 140 and the outer sheath 150 is constant, the larger the thickness of the inner sheath 140 is, the smaller the thickness of the outer sheath 150 is, and the worse the abrasion resistance of the spiral cable 100 is.

TABLE 2 resistance to scuffing of different spiral cables

The results of the scuff resistance and cyclic stretchability data described above were combined to form a linear relationship plot of the thickness of the inner jacket versus the number of bends and the number of drags of the corresponding cable, as shown in fig. 5.

From the above inspection results, it can be seen that when the polyester polyurethane inner sheath 140 with a certain thickness and the polyether polyurethane outer sheath 150 with a certain thickness are combined together, the formed spiral cable 100 is ensured to have low cost, good bending property and good hydrolysis resistance, and meet the requirement of long-term stable use in frequent stretching and vibration working conditions.

Second embodiment

Referring to fig. 1 and fig. 2, the structure of a double-layer sheathed spiral cable 100 provided in this embodiment is substantially the same as that of the first embodiment, except that in this embodiment, the number of wire cores is 15, that is, 15 core structures. The wire cores are arranged into two layers, specifically, 4 wire cores in the middle are arranged into one layer, the other 11 wire cores are arranged into one layer outside, and the stranding directions of the wire cores in each layer are the same.

Accordingly, the manufacturing process of this double-jacketed spiral cable 100 is substantially the same as that in the first embodiment, except that: the production of the cable core adopts a stranding and cabling process, the cable cores are uniformly stranded together in a layering mode through a cabling machine, the stranding direction of each layer of cable core is the same direction, and the stranding pitch-diameter ratio is 4-15 times.

To sum up, the double-layer sheath spiral cable and the manufacturing process thereof have the advantages of low cost, high strength, good bending performance and good roundness, and can meet the requirements of long-term stable use in frequent stretching and vibration working conditions.

The above description is only an example of the present application and is not intended to limit the scope of the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims (10)

1. The utility model provides a double-deck sheath spiral cable which characterized in that, it includes the cable core that forms by a plurality of sinle silks transposition, the cable core outward in proper order the cladding have band layer, inner sheath and oversheath, the material of inner sheath is polyester type polyurethane, the material of oversheath is polyether type polyurethane.

2. The double-jacketed spiral cable of claim 1, wherein the inner jacket is made of a thermoplastic polyester polyurethane elastomer material; the outer sheath is made of thermoplastic polyether type polyurethane elastomer material.

3. The double-jacketed spiral cable of claim 1, wherein the core includes a conductor and an insulating layer surrounding the conductor; optionally, the conductor is formed by twisting a plurality of copper wire bundles together, and the ratio of the bundle twisting pitch diameter is not more than 20 times; optionally, the insulating layer is made of PVC.

4. The double-jacketed spiral cable of claim 1, wherein all of the cores are arranged in at least two layers, the stranding directions of the cores being the same for each layer; and/or the stranding pitch diameter ratio of the wire core is 4-15 times.

5. The double-layer sheath spiral cable of claim 1, wherein the material of the wrapping layer is polyester plastic, paper or non-woven fabric; and/or the belting layer is formed by a lapping mode, and the coverage rate of the belting layer is 10-80%.

6. The double-jacketed spiral cable of claim 1, wherein the total thickness of the inner jacket and the outer jacket is 1.5-2 mm.

7. A process for manufacturing a double-jacketed spiral cable according to claim 1, comprising the steps of:

stranding a plurality of wire cores to form a cable core, and covering the cable core to form a belting layer;

adopting polyester polyurethane, and coating the belting layer to form an inner sheath;

adopting polyether polyurethane, and coating the outer sheath outside the inner sheath to form an outer sheath to obtain a linear cable;

and spirally rolling and molding the cable.

8. The manufacturing process of the double-layer sheath spiral cable according to claim 7, wherein the cladding forming method of the cladding layer is as follows: and uniformly wrapping a wrapping tape on the cable core by adopting a wrapping tape wrapping process to form a wrapping tape layer, wherein the coverage rate of the wrapping tape is 10% -80%.

9. The manufacturing process of the double-sheathed spiral cable according to claim 7, wherein the inner sheath is formed by: extruding and molding outside the wrapping layer through an extruder, wherein the temperature of each section of the extruder is 180-220 ℃, and the temperature of a head die of the extruder is 180-220 ℃;

and/or the coating forming method of the outer sheath comprises the following steps: and extruding and molding outside the wrapping layer through an extruder, wherein the temperature of each section of the extruder is 180-220 ℃, and the temperature of a head die of the extruder is 180-220 ℃.

10. The process for manufacturing a double-jacketed spiral cable according to claim 7, wherein the method for forming the spiral coil is: winding the cable on a winding rod to form a spiral shape, then baking at 130-140 ℃ for 60-100 min, and air cooling; the diameter of the winding rod is 3-4 times of the outer diameter of the cable.

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