CN113556837B - Integrally formed armored heat tracing belt and manufacturing method thereof - Google Patents
Integrally formed armored heat tracing belt and manufacturing method thereof Download PDFInfo
- Publication number
- CN113556837B CN113556837B CN202110862178.7A CN202110862178A CN113556837B CN 113556837 B CN113556837 B CN 113556837B CN 202110862178 A CN202110862178 A CN 202110862178A CN 113556837 B CN113556837 B CN 113556837B
- Authority
- CN
- China
- Prior art keywords
- core wire
- sheath
- core
- integrally formed
- injection molding
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 43
- 238000000034 method Methods 0.000 claims abstract description 38
- 238000000465 moulding Methods 0.000 claims abstract description 9
- 238000001746 injection moulding Methods 0.000 claims description 62
- 238000003466 welding Methods 0.000 claims description 35
- 239000011265 semifinished product Substances 0.000 claims description 26
- 239000000919 ceramic Substances 0.000 claims description 18
- 239000002131 composite material Substances 0.000 claims description 17
- 238000002347 injection Methods 0.000 claims description 15
- 239000007924 injection Substances 0.000 claims description 15
- 238000010438 heat treatment Methods 0.000 claims description 14
- 239000004033 plastic Substances 0.000 claims description 13
- 239000000463 material Substances 0.000 claims description 10
- 239000002245 particle Substances 0.000 claims description 9
- 239000000047 product Substances 0.000 claims description 9
- 238000007906 compression Methods 0.000 claims description 8
- 230000006835 compression Effects 0.000 claims description 7
- 229910052500 inorganic mineral Inorganic materials 0.000 claims description 6
- 239000011707 mineral Substances 0.000 claims description 6
- 239000003566 sealing material Substances 0.000 claims description 6
- 238000012360 testing method Methods 0.000 claims description 6
- 239000000395 magnesium oxide Substances 0.000 claims description 5
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 5
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 5
- 238000004806 packaging method and process Methods 0.000 claims description 4
- 238000007789 sealing Methods 0.000 claims description 4
- 239000003365 glass fiber Substances 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims description 3
- 239000004593 Epoxy Substances 0.000 claims description 2
- 238000001816 cooling Methods 0.000 description 5
- 239000004020 conductor Substances 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000012778 molding material Substances 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 239000003610 charcoal Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 238000011990 functional testing Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 238000005246 galvanizing Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/40—Heating elements having the shape of rods or tubes
- H05B3/54—Heating elements having the shape of rods or tubes flexible
- H05B3/56—Heating cables
- H05B3/565—Heating cables flat cables
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14008—Inserting articles into the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/02—Details
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
The invention provides an integrally formed armored heat tracing band and a manufacturing method thereof, wherein the integrally formed armored heat tracing band comprises a first core body, a second core body and a terminal; the first core body comprises a first core wire and a first sheath, and the second core body comprises a second core wire and a second sheath; the first core wire is electrically connected with the second core wire; the first sheath is formed at one end of the second sheath through an integral molding process so as to seal and fix the first core wire and the second core wire in a cavity formed by the first sheath and the second sheath; the terminal device is fixedly connected with one end, far away from the first core, of the second core. The first sheath is fixed on the second sheath through an integral molding process, so that the first core body and the second core body can be stably fixed without a connector; the integral molding process ensures that the joint of the first sheath and the second sheath is not easy to damage, thereby not only reducing the manufacturing cost, but also ensuring that the service life of the armoured heat tracing belt is longer, and solving the problem of how to improve the service life of the armoured heat tracing belt on the basis of reducing the manufacturing cost of the armoured heat tracing belt.
Description
Technical Field
The invention relates to the technical field of heat tracing bands, in particular to an integrally-formed armored heat tracing band and a manufacturing method thereof.
Background
Armor means that cables that are required to withstand large mechanical forces should have an armor layer, i.e., a layer of metal is added to the outermost face of the cable to protect the inner utility layer from damage during transport and installation. The production process of armor generally comprises: paying off, annealing, patenting, water cooling, hydrochloric acid derusting, water washing, sticking plating assistant solvent, drying, hot galvanizing, charcoal powder wiping, air cooling, water cooling, wire winding and the like.
The armoured heat tracing belt is a novel electric heating element, and can automatically adjust the heating power of the regulator along with the change of the ambient temperature under a certain voltage. The armoured heat tracing belt has an armoured cable structure, so that the armoured heat tracing belt is easy to assemble and form and can bear high-temperature welding, and has a wide application prospect.
However, the existing armoured heat tracing band is formed by connecting and fixing a heating section cable and a non-heating section cable through a connector. The method not only increases the structural components of the heat tracing belt, so that the manufacturing cost is higher, but also can lead to the failure of the armored heat tracing belt due to the failure of the connector in the actual use process, so that the service life of the product is shorter.
Disclosure of Invention
The invention aims to provide an integrally formed armoured heat tracing band and a manufacturing method thereof, which are used for solving the problem of how to improve the service life of the armoured heat tracing band on the basis of reducing the manufacturing cost of the armoured heat tracing band.
In order to solve the technical problems, the invention provides an integrally formed armored heat tracing band, which comprises a first core body, a second core body and a terminal; the first core body comprises a first core wire and a first sheath, and the second core body comprises a second core wire and a second sheath; one end of the first core wire is electrically connected with one end of the second core wire; the first sheath is formed at one end of the second sheath through an integral molding process so as to seal and fix the first core wire and the second core wire in a cavity formed by the first sheath and the second sheath; the terminal device is fixedly connected with one end, far away from the first core, of the second core.
Optionally, in the integrally formed armoured heat tracing band, the first core wire and the second core wire are welded and fixed by ultrasonic welding; the first core wire is used as a heating section, and the second core wire is used as a non-heating section.
Optionally, in the integrally formed armored heat tracing band, the first sheath is made of insulating plastic; the first core wire and the second core wire are made of mineral insulated cables.
Optionally, in the integrally formed armoured heat tracing band, a wire diameter of the first core wire is smaller than a wire diameter of the second core wire; the outer diameter of the first sheath is not greater than the inner diameter of the second sheath; the first core wire is arranged in a non-contact mode with the first sheath, and the second core wire is arranged in a non-contact mode with the second sheath.
Optionally, in the integrally formed armoured heat tracing band, the terminator comprises a fixing clip, a composite connection component, a ceramic component and a compression ring; the fixing clamp is used for fixing the second core body and the composite connecting assembly; the composite connecting component is provided with a hollow cavity, the ceramic component is fixed in the hollow cavity, and one end of the composite connecting component, which is far away from the fixing clamp, is fixed with the compression ring; the ceramic component is electrically connected with the second core wire.
Optionally, in the integrally formed armoured heat tracing band, a sealing material is filled between the fixing clip and the ceramic component, and the sealing material is magnesium oxide or epoxy resin.
In order to solve the technical problem, the present invention further provides a method for manufacturing the integrally formed armoured heat tracing band, which is used for manufacturing the integrally formed armoured heat tracing band according to any one of the above, the manufacturing method comprising:
the second core wire is electrically connected and fixed with the terminator, and the second sheath is mechanically connected and fixed with the terminator to form a first-stage semi-finished product;
carrying out ultrasonic welding and fixing on one end of the first core wire and the exposed end of the second core wire of the primary semi-finished product to form a secondary semi-finished product;
placing the secondary semi-finished product into an injection mold, and performing injection molding to form a first sheath, wherein the first sheath is in sealing connection with the second sheath, so that the first core wire and the second core wire are positioned in a sealed cavity formed by the first sheath and the second sheath; the injection molded product is the integrally formed armored heat tracing band;
and testing, inspecting and packaging the integrally formed armored heat tracing belt.
Optionally, in the method for manufacturing an integrally formed armoured heat tracing band, the method for performing ultrasonic welding and fixing on one end of the first core wire and the exposed end of the second core wire of the primary semi-finished product includes:
fixing the relative positions of one end of the first core wire and the exposed end of the second core wire, wherein the length of a superposition area of the first core wire and the second core wire is 0.2-2 mm;
ultrasonic welding is carried out on the overlapped area, wherein the welding time is 0.16-0.38 s, the welding amplitude is 12-20 mu m, the welding frequency is 15-40 KHz, and the welding pressure is 0.3-0.6 MPa;
standing for 1-3 s, and taking out the welded secondary semi-finished product.
Optionally, in the method for manufacturing an integrally formed armoured heat tracing band, the method for forming the first sheath by injection molding includes:
PVC, PE, PP, ABS or PA66 or any glass fiber mixture is selected as plastic particles for injection molding;
baking the plastic particles for 30-90 min at 60-100 ℃;
and (3) placing the secondary semi-finished product into an injection mold for injection molding, wherein the injection molding temperature is 160-300 ℃, the injection molding pressure is 0.3-1.2 MPa, and the injection molding time is 1-6 s.
Optionally, in the method for manufacturing the integrally formed armoured heat tracing belt, injection molding is divided into two sections, wherein the temperature of the first section injection molding is 220-280 ℃, the injection molding pressure is 0.3-1.2 MPa, the injection molding time is 1-3 s, the temperature of the second section injection molding is 180-260 ℃, the injection molding pressure is 0.5-0.8 MPa, and the injection molding time is 2-5 s.
The invention provides an integrally formed armored heat tracing band and a manufacturing method thereof, wherein the integrally formed armored heat tracing band comprises a first core body, a second core body and a terminal; the first core body comprises a first core wire and a first sheath, and the second core body comprises a second core wire and a second sheath; one end of the first core wire is electrically connected with one end of the second core wire; the first sheath is formed at one end of the second sheath through an integral molding process so as to seal and fix the first core wire and the second core wire in a cavity formed by the first sheath and the second sheath; the terminal device is fixedly connected with one end, far away from the first core, of the second core. The first sheath is fixed on the second sheath through the integrated forming process, so that the stable fixation of the first core body and the second core body can be realized without a connector, and the first sheath is integrated on the second sheath, so that the first sheath is not easy to damage, the manufacturing cost is reduced, the service life of the armoured heat tracing belt is longer, and the problem of how to improve the service life of the armoured heat tracing belt on the basis of reducing the manufacturing cost of the armoured heat tracing belt is solved.
Drawings
Fig. 1 is a schematic structural view of a conventional armoured heat trace belt;
fig. 2 is a schematic structural diagram of an integrally formed armoured heat tracing band according to the present embodiment;
fig. 3 is a partial enlarged view of a joint between a first core and a second core of an integrally formed armoured heat trace tape according to the present embodiment;
fig. 4 is a schematic structural view of a termination of the integrally formed armoured heat tracing band according to the present embodiment;
fig. 5 is a flowchart of a method for manufacturing an integrally formed armoured heat trace belt according to the present embodiment;
wherein, each reference sign is explained as follows:
110-a first core; 120-a second core; 130-terminator; 140-connectors;
210-a first core; 211-a first core wire; 212-a first sheath; 220-a second core; 221-a second core wire; 222-a second sheath; 230-terminator; 231-a fixing clip; 232-a composite connection assembly; 233-ceramic component; 234-compression ring.
Detailed Description
The integrally formed armoured heat trace ribbon and the method of manufacturing the same according to the present invention are described in further detail below with reference to the accompanying drawings and specific examples. It should be noted that the drawings are in a very simplified form and are all to a non-precise scale, merely for convenience and clarity in aiding in the description of embodiments of the invention. Furthermore, the structures shown in the drawings are often part of actual structures. In particular, the drawings are shown with different emphasis instead being placed upon illustrating the various embodiments.
It is noted that "first", "second", etc. in the description and claims of the present invention and the accompanying drawings are used to distinguish similar objects so as to describe embodiments of the present invention, and not to describe a specific order or sequence, it should be understood that the structures so used may be interchanged under appropriate circumstances. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
The structure of the existing armoured heat trace tape is shown in fig. 1 and generally includes a first core 110, a second core 120, a terminator 130 and a connector 140. The first core 110 is used as a heating section, the second core 120 is used as a non-heating section, and the two ends are connected and fixed. The terminator 130 is fixed to the end of the second core wire 120 away from the first core wire 110 to supply and control the power to the armoured heat tracing band. The connector 140 is located at the junction of the first core 110 and the second core 120 to reinforce the junction, and prevent the armoured heat tracing band from breaking or other faults at the junction during use.
Therefore, in order to realize the structure of the existing armoured heat tracing band, the connector is required to be additionally arranged in the manufacturing and assembling process, so that not only is the manufacturing cost increased, but also the effective length of the heating section of the armoured heat tracing band is shortened due to the coverage of the connector, and the heating efficiency of the armoured heat tracing band is lower.
Based on the above-described problems, the present embodiment provides an integrally formed armoured heat trace belt, as shown in fig. 2 and 3, including a first core 210, a second core 220 and a terminator 230; the first core 210 includes a first core wire 211 and a first sheath 212, and the second core 220 includes a second core wire 221 and a second sheath 222; one end of the first core wire 211 is electrically connected to one end of the second core wire 221; the first sheath 212 is formed at one end of the second sheath 222 through an integral molding process, so as to seal and fix the first core wire 211 and the second core wire 221 in a cavity formed by the first sheath 212 and the second sheath 222; the terminator 230 is fixedly connected to an end of the second core 220 remote from the first core 210.
According to the integrally formed armoured heat tracing band provided by the embodiment, the first sheath is fixed on the second sheath through an integrally forming process, so that stable fixation of the first core body and the second core body can be realized without a connector; the first sheath is integrally formed on the second sheath, so that the first sheath is not easy to damage, the manufacturing cost is reduced, and the service life of the armored heat tracing belt is longer; in addition, the effective length of the heating section formed by the first core wire is not covered because the connector is not needed to be fixed, so that the efficiency of the armoured heat tracing band is improved, and the problem of how to improve the service life of the armoured heat tracing band on the basis of reducing the manufacturing cost of the armoured heat tracing band is solved.
Specifically, in the present embodiment, the first core wire 211 serves as a heat generating section, the second core wire 212 serves as a non-heat generating section, and the first core wire 211 and the second core wire 212 are welded and fixed by ultrasonic welding.
Ultrasonic welding is to transfer high-frequency vibration waves to the surfaces of two objects to be welded, and under the condition of pressurization, the surfaces of the two objects are rubbed with each other to form fusion between molecular layers. Ultrasonic welding is not only fast, welding strength is high, the leakproofness is good, but also the welding mode of clean environmental protection.
Further, in this embodiment, the materials of the first core wire 211 and the second core wire 212 are mineral insulated cables.
The mineral insulated cable (Mineral insulated cable) is a cable which is formed by wrapping a copper conductor core wire with a copper sheath and isolating the conductor and the sheath by taking magnesium oxide powder as an inorganic insulating material, wherein the outermost layer can be a proper protective sleeve according to the requirement, and is commonly called as MICC or MI cable. The mineral insulated cable has excellent fire resistance, high temperature resistance and explosion resistance, long service life and high mechanical strength, and can bear high heat and high current-carrying capacity of the heat tracing band, so that the safety performance of the armored heat tracing band can be effectively improved.
In this embodiment, the material of the first sheath 212 is insulating plastic. Since the integral molding is required, the injection molding using plastic particles can realize the connection fixation of the first sheath 212 and the second sheath 222 on the basis of ensuring the conductive performance of the first core wire 211 and the second core wire 221. In addition, the first sheath 212 is formed by injection molding, so that tight connection between the first sheath 212 and the second sheath 222 can be ensured, and consistency of produced products is good. In a specific application process, the material of the second sheath 222 may be plastic, metal, or even glass, that is, the material of the second sheath 222 may be the same as or different from the material of the first sheath 212. When different materials are selected, the parameters of the injection molding process are different, which are well known to those skilled in the injection molding art and will not be described here.
Preferably, in order to achieve efficient heat generation of the first core wire 211, in the present embodiment, the wire diameter of the first core wire 211 is smaller than the wire diameter of the second core wire 221. The outer diameter of the first sheath 212 is no greater than the inner diameter of the second sheath 222; the first core wire 211 is disposed in non-contact with the first sheath 212, and the second core wire 221 is disposed in non-contact with the second sheath 222.
In the integrally formed armoured heat tracing band provided in this embodiment, as shown in fig. 4, the terminator 230 includes a fixing clip 231, a composite connection assembly 232, a ceramic assembly 233 and a compression ring 234; the fixing clip 231 is used to fix the second core 220 and the composite connection assembly 232; the composite connecting component 232 has a hollow cavity, the ceramic component 233 is fixed in the hollow cavity, and one end of the composite connecting component 232 away from the fixing clip 231 is fixed with the compression ring 234; the ceramic member 233 is electrically connected to the second core wire 221.
The terminator 230 is used for realizing power supply and electric control of the heat tracing band. Specifically, the ceramic component 233 is fixedly connected to the second core wire 221, and the manner of the fixed connection may be welding or assembling through a clamping structure, so that when there are multiple second core wires 221, different core wires can be fixed at different positions of the ceramic component 233 according to the actual structural design. Through holes are formed in the middle parts of the composite connection component 232 and the compression ring 234, so that external devices can extend into the hollow cavity and contact with the ceramic component 233, and the heating function of the armored heat tracing band is realized.
Preferably, in the present embodiment, the composite connection member 232 is filled with a sealing material between the fixing clip 231 and the ceramic member 233. Specifically, the sealing material may be magnesium oxide or epoxy resin. The magnesium oxide can be used as a heat dissipation conductor to dissipate heat generated by power supply, so that the effect of cooling is achieved, and the working safety of the armoured heat tracing belt is further protected; the epoxy may seal the junction of the retainer clip 231 and the composite connection member 232 to prevent moisture in the air from entering the terminator 230, thereby causing a defect such as a short circuit between the ceramic member 233 and the second core wire 221.
It should be noted that the structure of the terminator 230 and the connection manner of the terminator and the second core 220 are well known to those skilled in the art, and will not be described herein. Other terminator constructions are also contemplated as falling within the scope of the present invention without departing from the spirit of the present invention.
The embodiment also provides a method for manufacturing the shaped armoured heat tracing band, as shown in fig. 5, the method comprises the following steps:
s1, electrically connecting and fixing a second core wire and a terminator, and mechanically connecting and fixing a second sheath and the terminator to form a first-stage semi-finished product;
s2, performing ultrasonic welding and fixing on one end of the first core wire and the exposed end of the second core wire of the primary semi-finished product to form a secondary semi-finished product;
s3, placing the secondary semi-finished product into an injection mold, and performing injection molding to form a first sheath, wherein the first sheath is in sealing connection with the second sheath so that the first core wire and the second core wire are positioned in a sealed cavity formed by the first sheath and the second sheath; the injection molded product is the integrally formed armored heat tracing band;
s4, testing, inspecting and packaging the integrally formed armored heat tracing belt.
According to the manufacturing method of the integrally formed armoured heat tracing band, the first core wire 211 and the second core wire 221 are welded through ultrasonic welding, so that environment-friendly, reliable and efficient welding can be realized; the first sheath 212 is processed through an injection molding integrated process, so that the manufacturing and assembling costs of the connector can be saved on the basis of guaranteeing the service life of the product, and the effective length of the heating section of the first core wire 211 can be increased, thereby improving the effective efficiency of the armouring heat tracing belt.
The method for manufacturing the integrally formed armoured heat trace tape according to the present invention will be described below with reference to a specific manufacturing process.
First, the second core wire is electrically connected and fixed with the terminator, and the second sheath is mechanically connected and fixed with the terminator to form a first-stage semi-finished product.
Specifically, one end of the second core wire is electrically connected and fixed with the ceramic component, and the second sheath is sleeved in the reserved hole of the fixing clamp. The assembly process is similar to the prior art and will not be described in detail here.
And then, carrying out ultrasonic welding and fixing on one end of the first core wire and the exposed end of the second core wire of the primary semi-finished product to form a secondary semi-finished product.
Specifically, the method for performing ultrasonic welding fixation on one end of the first core wire and the exposed end of the second core wire of the primary semi-finished product comprises the following steps:
fixing the relative positions of one end of the first core wire and the exposed end of the second core wire, wherein the length of a superposition area of the first core wire and the second core wire is 0.2-2 mm, and the length of the superposition area is used for melting of ultrasonic welding;
ultrasonic welding is carried out on the overlapped area, wherein the welding time is 0.16-0.38 s, the welding amplitude is 12-20 mu m, the welding frequency is 15-40 KHz, and the welding pressure is 0.3-0.6 MPa; because the wire diameters of the core wires are different, the specific welding parameters of the core wires need to be selected and determined in the range;
standing for 1-3 s, cooling the part to be welded firmly, and taking out the welded secondary semi-finished product.
Then, placing the secondary semi-finished product into an injection mold, and performing injection molding to form a first sheath, wherein the first sheath is in sealing connection with the second sheath so that the first core wire and the second core wire are positioned in a sealed cavity formed by the first sheath and the second sheath; the injection molded product is the integrally formed armored heat tracing band.
The design and processing of the injection mold are well known to those skilled in the relevant art, and will not be described herein. In this embodiment, the method for placing the secondary semi-finished product into an injection mold for injection molding to form the first sheath includes:
PVC, PE, PP, ABS or PA66 or any glass fiber mixture is selected as plastic particles for injection molding;
baking the plastic particles for 30-90 min at 60-100 ℃;
and (3) placing the secondary semi-finished product into an injection mold for injection molding, wherein the injection molding temperature is 160-300 ℃, the injection molding pressure is 0.3-1.2 MPa, and the injection molding time is 1-6 s.
It should be noted that different plastic particles are selected, and their baking process parameters and injection process parameters are adjusted accordingly. Considering that the second sheath may be made of different materials, different plastic particles are required to be selected as the material of the first sheath on the basis of ensuring the structural integrity of the second sheath.
Considering that the first sheath of the armoured heat tracing band is long cylindrical in structure, in order to ensure that the first sheath can be fully filled and that defects such as scorching and the like do not occur at the time of injection molding, in the embodiment, injection molding is divided into two sections, wherein the temperature of injection molding in the first section is 220-280 ℃, the injection molding pressure is 0.3-1.2 MPa, the injection molding time is 1-3 s, the temperature of injection molding in the second section is 180-260 ℃, the injection molding pressure is 0.5-0.8 MPa, and the injection molding time is 2-5 s.
In a specific injection molding process, an injection molding machine with proper tonnage is selected according to the specific size, the amount of used materials and the like of the first sheath, so that the stability of injection molding of the product is higher. Of course, when the length of the first sheath is longer, injection molding into more segments may also be performed.
In the following, two specific injection molding parameters are given for reference:
injection molding parameter one (suitable for the length of the first sheath is less than or equal to 90 mm):
an injection molding material ABS is baked for 45+/-5 min, and the baking temperature is 80+/-10 ℃;
two-stage injection molding: first section injection molding: the temperature is 240+/-5 ℃, the pressure is 0.5+/-0.05 MPa, and the time is 2+/-0.5 s; second stage injection molding: the temperature is 220+/-5 ℃, the pressure is 0.6+/-0.05 MPa, and the time is 2.4+/-0.2 s.
Injection molding parameter two (suitable for the length of the first sheath is between 90 and 180 mm):
the injection molding material PA66 plus GF30 is baked for 60 plus or minus 10min, and the baking temperature is 80 plus or minus 5 ℃;
two-stage injection molding: first section injection molding: the temperature is 260+/-5 ℃, the pressure is 0.7+/-0.05 MPa, and the time is 2.5+/-0.5 s; second stage injection molding: the temperature is 230+/-5 ℃, the pressure is 0.5+0.05/-0MPa, and the time is 3+/-0.5 s.
And finally, inspecting and packaging the injection molded product, namely the final integrally formed armored heat tracing belt. The tests include visual and functional tests, the specific test steps and test criteria of which are well known to those skilled in the art and will not be described in detail herein.
In summary, the integrally formed armored heat tracing band and the manufacturing method thereof provided by the embodiment comprise a first core, a second core and a terminal; the first core body comprises a first core wire and a first sheath, and the second core body comprises a second core wire and a second sheath; one end of the first core wire is electrically connected with one end of the second core wire; the first sheath is formed at one end of the second sheath through an integral molding process so as to seal and fix the first core wire and the second core wire in a cavity formed by the first sheath and the second sheath; the terminal device is fixedly connected with one end, far away from the first core, of the second core. The first sheath is fixed on the second sheath through the integrated forming process, so that the stable fixation of the first core body and the second core body can be realized without a connector, and the first sheath is integrated on the second sheath, so that the first sheath is not easy to damage, the manufacturing cost is reduced, the service life of the armoured heat tracing belt is longer, and the problem of how to improve the service life of the armoured heat tracing belt on the basis of reducing the manufacturing cost of the armoured heat tracing belt is solved.
The above description is only illustrative of the preferred embodiments of the present invention and is not intended to limit the scope of the present invention, and any alterations and modifications made by those skilled in the art based on the above disclosure shall fall within the scope of the appended claims.
Claims (8)
1. The manufacturing method of the integrally formed armored heat tracing band is characterized in that the integrally formed armored heat tracing band comprises a first core body, a second core body and a terminal; the first core body comprises a first core wire and a first sheath, and the second core body comprises a second core wire and a second sheath; one end of the first core wire is electrically connected with one end of the second core wire; the first sheath is formed at one end of the second sheath through an integral molding process so as to seal and fix the first core wire and the second core wire in a cavity formed by the first sheath and the second sheath; the terminal device is fixedly connected with one end, far away from the first core, of the second core; the first core wire and the second core wire are welded and fixed through ultrasonic welding; the first core wire is used as a heating section, and the second core wire is used as a non-heating section;
the manufacturing method for manufacturing the integrally formed armored heat tracing band comprises the following steps:
the second core wire is electrically connected and fixed with the terminator, and the second sheath is mechanically connected and fixed with the terminator to form a first-stage semi-finished product;
carrying out ultrasonic welding and fixing on one end of the first core wire and the exposed end of the second core wire of the primary semi-finished product to form a secondary semi-finished product;
placing the secondary semi-finished product into an injection mold, and performing injection molding to form a first sheath, wherein the first sheath is in sealing connection with the second sheath, so that the first core wire and the second core wire are positioned in a sealed cavity formed by the first sheath and the second sheath; the injection molded product is the integrally formed armored heat tracing band;
and testing, inspecting and packaging the integrally formed armored heat tracing belt.
2. The method for manufacturing an integrally formed armoured heat trace ribbon as claimed in claim 1, wherein the material of the first sheath is insulating plastic; the first core wire and the second core wire are made of mineral insulated cables.
3. The method of manufacturing an integrally formed armor heat tracing band of claim 1, wherein a wire diameter of the first core wire is smaller than a wire diameter of the second core wire; the outer diameter of the first sheath is not greater than the inner diameter of the second sheath; the first core wire is arranged in a non-contact mode with the first sheath, and the second core wire is arranged in a non-contact mode with the second sheath.
4. The method of manufacturing an integrally formed armor heat trace tape of claim 1, wherein the terminator comprises a retaining clip, a composite connection assembly, a ceramic assembly, and a compression ring; the fixing clamp is used for fixing the second core body and the composite connecting assembly; the composite connecting component is provided with a hollow cavity, the ceramic component is fixed in the hollow cavity, and one end of the composite connecting component, which is far away from the fixing clamp, is fixed with the compression ring; the ceramic component is electrically connected with the second core wire.
5. The method of manufacturing an integrally formed armor heat trace tape of claim 4, wherein the composite connection assembly is filled with a sealing material between the retainer clip and the ceramic assembly, the sealing material being magnesium oxide or epoxy.
6. The method of manufacturing an integrally formed armor heat tracing band according to claim 1, wherein the method of ultrasonically welding and fixing one end of the first core wire and the exposed end of the second core wire of the primary semi-finished product comprises:
fixing the relative positions of one end of the first core wire and the exposed end of the second core wire, wherein the length of a superposition area of the first core wire and the second core wire is 0.2-2 mm;
ultrasonic welding is carried out on the overlapped area, wherein the welding time is 0.16-0.38 s, the welding amplitude is 12-20 mu m, the welding frequency is 15-40 KHz, and the welding pressure is 0.3-0.6 MPa;
standing for 1-3 s, and taking out the welded secondary semi-finished product.
7. The method of manufacturing an integrally formed armor heat trace ribbon of claim 1, wherein the injection molding process forms the first jacket comprises:
PVC, PE, PP, ABS, PA66 or any glass fiber mixture is selected as plastic particles for injection molding;
baking the plastic particles for 30-90 min at 60-100 ℃;
and (3) placing the secondary semi-finished product into an injection mold for injection molding, wherein the injection molding temperature is 160-300 ℃, the injection molding pressure is 0.3-1.2 MPa, and the injection molding time is 1-6 s.
8. The method for manufacturing an integrally formed armoured heat trace ribbon according to claim 7, wherein the injection molding is divided into two sections, the temperature of the first section is 220-280 ℃, the injection molding pressure is 0.3-1.2 MPa, the injection molding time is 1-3 s, the temperature of the second section is 180-260 ℃, the injection molding pressure is 0.5-0.8 MPa, and the injection molding time is 2-5 s.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202110862178.7A CN113556837B (en) | 2021-07-29 | 2021-07-29 | Integrally formed armored heat tracing belt and manufacturing method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202110862178.7A CN113556837B (en) | 2021-07-29 | 2021-07-29 | Integrally formed armored heat tracing belt and manufacturing method thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN113556837A CN113556837A (en) | 2021-10-26 |
| CN113556837B true CN113556837B (en) | 2024-04-12 |
Family
ID=78133197
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202110862178.7A Active CN113556837B (en) | 2021-07-29 | 2021-07-29 | Integrally formed armored heat tracing belt and manufacturing method thereof |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN113556837B (en) |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6104011A (en) * | 1997-09-04 | 2000-08-15 | Watlow Electric Manufacturing Company | Sheathed thermocouple with internal coiled wires |
| JP2010257582A (en) * | 2009-04-21 | 2010-11-11 | Okazaki Mfg Co Ltd | Terminal sleeve for heater |
| CN207678022U (en) * | 2018-01-05 | 2018-07-31 | 浙江伦特机电有限公司 | Multi-spot segmentation formula electric heating tube |
| CN111669845A (en) * | 2020-07-20 | 2020-09-15 | 无锡大洋高科热能装备有限公司 | High-temperature-resistant and high-dose-resistant gamma-ray radiation armored heater |
| CN212573014U (en) * | 2020-06-12 | 2021-02-19 | 江苏奥崎电气科技有限公司 | Armored heating cable built-in cold and hot end |
-
2021
- 2021-07-29 CN CN202110862178.7A patent/CN113556837B/en active Active
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6104011A (en) * | 1997-09-04 | 2000-08-15 | Watlow Electric Manufacturing Company | Sheathed thermocouple with internal coiled wires |
| JP2010257582A (en) * | 2009-04-21 | 2010-11-11 | Okazaki Mfg Co Ltd | Terminal sleeve for heater |
| CN207678022U (en) * | 2018-01-05 | 2018-07-31 | 浙江伦特机电有限公司 | Multi-spot segmentation formula electric heating tube |
| CN212573014U (en) * | 2020-06-12 | 2021-02-19 | 江苏奥崎电气科技有限公司 | Armored heating cable built-in cold and hot end |
| CN111669845A (en) * | 2020-07-20 | 2020-09-15 | 无锡大洋高科热能装备有限公司 | High-temperature-resistant and high-dose-resistant gamma-ray radiation armored heater |
Also Published As
| Publication number | Publication date |
|---|---|
| CN113556837A (en) | 2021-10-26 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| EP4135129A1 (en) | Injection-molded wire harness and molding method | |
| CN109286083A (en) | A kind of three-core cable welded joint and its mounting process | |
| CN109616962A (en) | A kind of hot melten type cable centre connection mounting process | |
| CN206272207U (en) | A kind of DC ultra-high-voltage crosslinked cable connecting hose | |
| WO2015013408A1 (en) | Electric vehicle shielded power cable connector | |
| JP6938547B2 (en) | Methods and equipment for sealing contacts at electrical cable connections | |
| CN113555840B (en) | Manufacturing process of self-melting insulating tape wrapping intermediate joint | |
| US20140346712A1 (en) | Cable with injection molded coupling part | |
| US4216351A (en) | Plastic collar integral with a cable jacket | |
| US4378323A (en) | Method of producing plastic collar integral with a cable jacket | |
| CN113556837B (en) | Integrally formed armored heat tracing belt and manufacturing method thereof | |
| CN209200188U (en) | A kind of recovery cable body structure jointing | |
| JP4460263B2 (en) | Waterproof cable manufacturing method and waterproof cable | |
| JP2012200110A (en) | Method for manufacturing water stop structure of splice portion, water stop structure of splice portion, and wiring harness | |
| CN110560814A (en) | welding method of low-temperature-resistant carbon fiber and copper wire | |
| CN214900135U (en) | Intermediate joint of wrapped insulated cable | |
| US11075470B2 (en) | Wire harness with covering materials and tube containing cross-linked polyethylene | |
| JP2024509248A (en) | Cable assembly and cable assembly manufacturing method | |
| CN113543391A (en) | Three-core armored heating belt | |
| CN208189794U (en) | A kind of conductor connecting structure | |
| CN205862820U (en) | A kind of crosslinked polyethylene fusing type insulated cable joint | |
| CN202996397U (en) | Cross-linked polyethylene insulated polyvinyl chloride sheath integrated branch cable | |
| CN204068186U (en) | cable connection assembly | |
| CN208889876U (en) | A kind of fusion formula cable connector | |
| CN218886855U (en) | Electronic wire with insulating wear-resistant function |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |