CN114944243A - 一种抗冲击高耐磨电缆及加工工艺 - Google Patents
一种抗冲击高耐磨电缆及加工工艺 Download PDFInfo
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Abstract
本发明涉及电缆制造技术领域,具体涉及一种抗冲击高耐磨电缆及加工工艺,包括防冲击机构和主导线均安装在外壳层内,外壳层包括防护层、隔热层和缓冲层,隔热层位于防护层内侧,缓冲层位于隔热层内侧,缓冲层内嵌设有加强绳,防护层上开设有安装槽,安装槽内转动安装有耐磨环,耐磨环内嵌设有加固环,加强绳为钢丝绳,防护层为PVC材质,隔热层为玻璃纤维带缠绕而成,且隔热层内设有阻燃剂,阻燃剂为氢氧化镁阻燃粉剂,主导线包括导电芯、内衬层、内绝缘层、屏蔽层和外绝缘层,本发明能够较好的吸收冲击力,而且具有耐磨处理,防冲击机构能够提供较好的吸能保护内部主导线的作用,在外壳体受到冲击时将冲击力分散处理。
Description
技术领域
本发明涉及电缆制造技术领域,特别是涉及一种抗冲击高耐磨电缆及加工工艺。
背景技术
通常是由几根或几组导线绞合而成的类似绳索的电缆,每组导线之间相互绝缘,并常围绕着一根中心扭成,整个外面包有高度绝缘的覆盖层,电缆具有内通电,外绝缘的特征,而在一些特殊的使用环境中需要电缆具备一定的抗冲击和耐磨性能,比如在使用时需要暴露在外界环境中的特种电缆,由于使用环境多变,使用过程可能会伴随着外物撞击和转移拖动,而专利申请号:CN202021623063.X,公开日:2021.03.23的一种抗冲击耐候性电缆,其文件中所叙述的有益效果为通过中空的防冲击条作为吸能结构,然后通过其他填充料来进行辅助吸能,但此种吸能搭配强度过低,无法做到有效保护,而且缺少电缆的外部防护,尤其是对于电缆的外部防磨处理不足。
发明内容
为克服现有技术存在的技术缺陷,本发明提供一种抗冲击高耐磨电缆及加工工艺能够较好的吸收冲击力,而且具有耐磨处理,防冲击机构能够提供较好的吸能保护内部主导线的作用,而耐磨环能够减小线缆和地面之间的摩擦力。
本发明采用的技术解决方案是:包括主导线、防冲击机构和外壳层,主导线主要作为电流的传递导体,防冲击组件主要作为外部冲击冲击发生时的吸能部件,外壳层能够起到主体的防护作用,以及避免过度磨损的作用,方便在使用时相关人员进行电缆的转移拉扯,所述防冲击机构和所述主导线均安装在所述外壳层内,所述外壳层包括防护层、隔热层和缓冲层,所述隔热层位于所述防护层内侧,所述缓冲层位于所述隔热层内侧,所述缓冲层内嵌设有加强绳,缓冲层主要起到吸能减震作用,在冲击或者部件震动发生时,缓冲层能够起到主要的辅助吸能作用,所述加强绳为钢丝绳,钢丝绳为纵向埋设,在加强电缆的总体强度时,也能够起到一定的防护作用,所述防护层为PVC材质,物理机械性能好,加工性能好,成本和售价低,防护层主要起到对内部材料隔离保护作用,避免外界的灰尘和液体隔离,是电缆的第一层绝缘保护层,所述隔热层为玻璃纤维带缠绕而成,且隔热层内设有阻燃剂,玻璃纤维带不易燃烧,配合阻燃剂能够避免热量传递,能够提高电缆的耐热程度,所述阻燃剂为氢氧化镁阻燃粉剂,氢氧化镁是一种新型填充型阻燃剂,通过受热分解时释放出结合水,吸收大量的潜热,来降低它所填充的合成材料在火焰中的表面温度,具有抑制聚合物分解和对所产生的可燃气体进行冷却的作用,所述防护层上开设有安装槽,在开设至安装槽应避免穿透防护层,所述安装槽内转动安装有耐磨环,所述耐磨环内嵌设有加固环,为了提高加固环强度,应使用金属环,耐磨环能够在拉扯移动电缆时,避免电缆大面积的接触地面,进而造成电缆磨损以及相关人员拉扯电缆费力的情况。
优选的,所述主导线包括导电芯、内衬层、内绝缘层、屏蔽层和外绝缘层,所述内衬层位于所述导电芯外侧,所述内绝缘层位于所述内衬层外侧,所述屏蔽层位于所述内绝缘层外侧,所述内衬层为特氟龙材质,内衬层能够减少导电芯和外层材料之间的摩擦,所述内绝缘层为橡胶材质,内绝缘层能够起到绝缘作用防护作用,所述屏蔽层为铜质编织网,由于在电缆的使用时需要剥去外皮,因此铜制编织网能够在剥去防护壳后,仍然保证主导线的屏蔽作用,所述外绝缘层为PVC材质,外绝缘层为导电芯的外层防护作用层。
优选的,所述防冲击机构包括筒壳、吸能机构和外护板,所述吸能机构均固定在所述筒壳的外壁上,所述外护板均固定在所述吸能机构上,外护板为弧形,且贴合在所述外壳层的内壁上,所述外护板之间固定连接有防护绳,所述防护绳为钢丝绳,钢丝材质的防护绳能够更好的提高防护强度,更好的拉持外护板,在受到外力冲击时外护板能够成为主要的受力部件,而外护板之间需要预留空间,这是为了让防护板能够有空间运动。
优选的,所述筒壳内设有加强钢芯,加强钢芯能够增强电缆的整体强度,而且能够为筒壳提供载体从而方便固定,所述筒壳的侧壁上设有固定片,固定片之间需要留有空隙,以便在固定防冲击组件时方便压持,所述吸能机构包括吸能座,吸能弹簧和吸能杆,所述吸能座的侧壁上设有弧槽,弧槽应能够和主导线的外壁相贴合,所述吸能座内设有空腔,所述吸能弹簧固定在所述空腔内的底部上,所述吸能杆固定在所述吸能弹簧上,且所述吸能杆延伸至所述吸能座外,在外壳体受到冲击时,能够将冲击力传递给外护板,然后外护板将冲击力传递给吸能机构,吸能机构能够吸收冲击力,而且吸能机构为分散在筒壳上,因此冲击力能够传递给筒壳,然后再由其他吸能机构和外护板所吸收,从而避免主导线受到冲击影响。
优选的,S1:在所述导电芯外套设所述内衬层,可采用绕包,因为内衬层主要起到避免摩擦的作用,然后进行包覆内所述绝缘层,外层包覆的绝缘层能够固定内衬层,而且能够将导电芯保护起来,使导线芯成为简单有防护的导电体,然后套设所述屏蔽层,屏蔽层能够隔离电磁,避免电磁干扰,包覆所述外绝缘层,外绝缘层主要起到绝缘防护作用,这样才完成单根的导电体;
S2:使用外部挤压设备将防冲击机构均匀固定在加强钢芯上,即通过挤压所述固定片将筒壳固定,在使用时需要均匀的分隔防冲击机构,一是方便电缆在成型后的可扭曲,而且也方便在分隔处之间安装耐磨环,这样即保证了电缆的可扭曲,也保证了线缆的防护强度,同时挤压固定片也更加方便加工,降低了加工难度,也可以方便后期的规格改变;
S3:将所述主导线放置在所述筒壳内壁上的所述弧槽内,可用粘胶辅助固定,然后使用橡胶对所述主导线和所述防冲击机构填充处理,为了避免主导线产生晃动,从而对主导线产生摩擦损伤,填充橡胶能够使主导线和防冲击机构成为一个整体,将外形定型为圆柱形,然后在填充物外挤包铝制壳,铝制壳能够作为各个主导线外的防护屏蔽壳,而挤包形成的铝制壳能够更好的避免电磁干扰;
S4:向铝制壳外挤包缓冲层,然后埋设加强绳,加强绳应纵向贯穿电缆,能够更好的起到防护作用,然后绕覆隔热层,即使用绕包机将玻璃纤维带缠绕在缓冲层上,因为再外层即为防护层,因此隔热层能够将外部热量隔绝,避免其进入内部,以及挤包防护层,防护层主要起到隔绝外界环境,起到主要的外层防护作用,然后在防护层上开设安装槽,耐磨环能够在安装槽内进行转动,从而方便横向转移线缆,然后设置耐磨环即可,而耐磨环能够减小线缆和地面之间的摩擦力,从而更加方便相关人员转移线缆。
本发明的有益效果是:
本发明的防冲击机构能够提供较好的吸能保护内部主导线的作用,在外壳体受到冲击时,能够将冲击力传递给外护板,然后外护板将冲击力传递给吸能机构,吸能杆能够压缩吸能弹簧,进而对冲击力进行缓冲处理,吸能机构能够冲击力后,即减弱冲击力的分散,吸能机构为分散在筒壳上,因此冲击力能够传递给筒壳,然后再由其他吸能机构和外护板所吸收,从而避免主导线受到冲击影响,钢丝材质的防护绳能够更好的提高防护强度,更好的拉持外护板,在受到外力冲击时外护板能够成为主要的受力部件,而外护板之间需要预留空间,这是为了让防护板能够有空间运动,在使用时缓冲层位于隔热层内侧,缓冲层内嵌设有加强绳,缓冲层主要起到吸能减震作用,在冲击或者部件震动发生时,缓冲层能够起到主要的辅助吸能作用,耐磨环能够在安装槽内进行转动,从而方便横向转移线缆,然后设置耐磨环即可,而耐磨环能够减小线缆和地面之间的摩擦力,从而更加方便相关人员转移线缆。
附图说明
图1为本发明立体结构示意图。
图2为本发明图1中A处的结构示意图。
图3为本发明防冲击机构的结构示意图。
图4为本发明吸能机构的结构示意图。
图5为本发明外壳层的剖视结构示意图。
图6为本发明的工艺流程示意图。
附图标记说明:图中:1、主导线;2、防冲击机构;3、外壳层;4、防护层;5、隔热层;6、缓冲层;7、加强绳;8、耐磨环;9、加固环;10、导电芯;11、内衬层;12、内绝缘层;13、外绝缘层;14、筒壳;15、吸能机构;16、外护板;17、防护绳;18、加强钢芯;19、固定片;20、吸能座;21、吸能弹簧;22、吸能杆;23、弧槽;24、屏蔽层。
具体实施方式
下面结合附图对本发明作进一步说明:
如图1-6所示,本实施例提供一种抗冲击高耐磨电缆及加工工艺,包括主导线1、防冲击机构2和外壳层3,主导线1主要作为电流的传递导体,防冲击组件主要作为外部冲击冲击发生时的吸能部件,外壳层3能够起到主体的防护作用,以及避免过度磨损的作用,方便在使用时相关人员进行电缆的转移拉扯,防冲击机构2和主导线1均安装在外壳层3内,外壳层3包括防护层4、隔热层5和缓冲层6,隔热层5位于防护层4内侧,缓冲层6位于隔热层5内侧,缓冲层6内嵌设有加强绳7,缓冲层6主要起到吸能减震作用,在冲击或者部件震动发生时,缓冲层6能够起到主要的辅助吸能作用,加强绳7为钢丝绳,钢丝绳为纵向埋设,在加强电缆的总体强度时,也能够起到一定的防护作用。
防护层4为PVC材质,物理机械性能好,加工性能好,成本和售价低,防护层4主要起到对内部材料隔离保护作用,避免外界的灰尘和液体隔离,是电缆的第一层绝缘保护层,隔热层5为玻璃纤维带缠绕而成,且隔热层5内设有阻燃剂,玻璃纤维带不易燃烧,配合阻燃剂能够避免热量传递,能够提高电缆的耐热程度,阻燃剂为氢氧化镁阻燃粉剂,氢氧化镁是一种新型填充型阻燃剂,通过受热分解时释放出结合水,吸收大量的潜热,来降低它所填充的合成材料在火焰中的表面温度,具有抑制聚合物分解和对所产生的可燃气体进行冷却的作用,防护层4上开设有安装槽,在开设至安装槽应避免穿透防护层4,安装槽内转动安装有耐磨环8,耐磨环8内嵌设有加固环9,为了提高加固环9强度,应使用金属环,耐磨环8能够在拉扯移动电缆时,避免电缆大面积的接触地面,进而造成电缆磨损以及相关人员拉扯电缆费力的情况。
主导线1包括导电芯10、内衬层11、内绝缘层12、屏蔽层24和外绝缘层13,内衬层11位于导电芯10外侧,内绝缘层12位于内衬层11外侧,屏蔽层24位于内绝缘层12外侧,内衬层11为特氟龙材质,内衬层11能够减少导电芯10和外层材料之间的摩擦,内绝缘层12为橡胶材质,内绝缘层12能够起到绝缘作用防护作用,屏蔽层24为铜质编织网,由于在电缆的使用时需要剥去外皮,因此铜制编织网能够在剥去防护壳后,仍然保证主导线1的屏蔽作用,外绝缘层13为PVC材质,外绝缘层13为导电芯10的外层防护作用层,主要在使用时作为基本隔离防护作用。
防冲击机构2包括筒壳14、吸能机构15和外护板16,吸能机构15均固定在筒壳14的外壁上,外护板16均固定在吸能机构15上,外护板16为弧形,且贴合在外壳层3的内壁上,外护板16之间固定连接有防护绳17,防护绳17为钢丝绳,钢丝绳能够起到辅助受力的作用,钢丝材质的防护绳17能够更好的提高防护强度,更好的拉持外护板16,在受到外力冲击时外护板16能够成为主要的受力部件,而外护板16之间需要预留空间,这是为了让防护板能够有空间运动。
筒壳14内设有加强钢芯18,加强钢芯18能够增强电缆的整体强度,而且能够为筒壳14提供载体从而方便固定,筒壳14的侧壁上设有固定片19,固定片19之间需要留有空隙,以便在固定防冲击组件时方便压持,吸能机构15包括吸能座20,吸能弹簧21和吸能杆22,吸能座20的侧壁上设有弧槽23,弧槽23应能够和主导线1的外壁相贴合,吸能座20内设有空腔,吸能弹簧21固定在空腔内的底部上,吸能杆22固定在吸能弹簧21上,且吸能杆22延伸至吸能座20外,在外壳体受到冲击时,能够将冲击力传递给外护板16,然后外护板16将冲击力传递给吸能机构15,吸能杆22能够压缩吸能弹簧21,进而对冲击力进行缓冲处理,吸能机构15能够冲击力后,即减弱冲击力的分散,吸能机构15为分散在筒壳14上,因此冲击力能够传递给筒壳14,然后再由其他吸能机构15和外护板16所吸收,从而避免主导线1受到冲击影响。
S1:在导电芯10外套设内衬层11,可采用绕包,因为内衬层11主要起到避免摩擦的作用,然后进行包覆内绝缘层12,外层包覆的绝缘层能够固定内衬层11,而且能够将导电芯10保护起来,使导线芯成为简单有防护的导电体,然后套设屏蔽层24,屏蔽层24能够隔离电磁,避免电磁干扰,包覆外绝缘层13,外绝缘层13主要起到绝缘防护作用,这样才完成单根的导电体;
S2:使用外部挤压设备将防冲击机构2均匀固定在加强钢芯18上,即通过挤压固定片19将筒壳14固定,在使用时需要均匀的分隔防冲击机构2,一是方便电缆在成型后的可扭曲,而且也方便在分隔处之间安装耐磨环8,这样即保证了电缆的可扭曲,也保证了线缆的防护强度,同时挤压固定片19也更加方便加工,降低了加工难度,也可以方便后期的规格改变;
S3:将主导线1放置在筒壳14内壁上的弧槽23内,用粘胶辅助固定,然后使用橡胶对主导线1和防冲击机构2填充处理,为了避免主导线1产生晃动,从而对主导线1产生摩擦损伤,填充橡胶能够使主导线1和防冲击机构2成为一个整体,将外形定型为圆柱形,然后在填充物外挤包铝制壳,铝制壳能够作为各个主导线1外的防护屏蔽壳,而挤包形成的铝制壳能够更好的避免电磁干扰;
S4:向铝制壳外挤包缓冲层6,然后埋设加强绳7,加强绳7应纵向贯穿电缆,能够更好的起到防护作用,然后绕覆隔热层5,即使用绕包机将玻璃纤维带缠绕在缓冲层6上,因为再外层即为防护层4,因此隔热层5能够将外部热量隔绝,避免其进入内部,以及挤包防护层4,防护层4主要起到隔绝外界环境,起到主要的外层防护作用,然后在防护层4上开设安装槽,耐磨环8能够在安装槽内进行转动,从而方便横向转移线缆,然后设置耐磨环8即可,而耐磨环8能够减小线缆和地面之间的摩擦力,从而更加方便相关人员转移线缆。
以上显示和描述了本发明创造的基本原理和主要特征及本发明的优点,本行业的技术人员应该了解,本发明不受上述实施例的限制,上述实施例和说明书中描述的只是说明本发明的原理,在不脱离本发明创造精神和范围的前提下,本发明还会有各种变化和改进,这些变化和改进都落入要求保护的本发明范围内,本发明要求保护范围由所附的权利要求书及其等效物界定。
Claims (8)
1.一种抗冲击高耐磨电缆,包括主导线(1)、防冲击机构(2)和外壳层(3),其特征在于:所述防冲击机构(2)和所述主导线(1)均安装在所述外壳层(3)内,所述外壳层(3)包括防护层(4)、隔热层(5)和缓冲层(6),所述隔热层(5)位于所述防护层(4)内侧,所述缓冲层(6)位于所述隔热层(5)内侧,所述缓冲层(6)内嵌设有加强绳(7),所述防护层(4)上开设有安装槽,所述安装槽内转动安装有耐磨环(8),所述耐磨环(8)内嵌设有加固环(9)。
2.根据权利要求1所述的一种抗冲击高耐磨电缆,其特征在于:所述加强绳(7)为钢丝绳,所述防护层(4)为PVC材质,所述隔热层(5)为玻璃纤维带缠绕而成,且隔热层(5)内设有阻燃剂,所述阻燃剂为氢氧化镁阻燃粉剂。
3.根据权利要求1所述的一种抗冲击高耐磨电缆,其特征在于:所述主导线(1)包括导电芯(10)、内衬层(11)、内绝缘层(12)、屏蔽层(24)和外绝缘层(13),所述内衬层(11)位于所述导电芯(10)外侧,所述内绝缘层(12)位于所述内衬层(11)外侧,所述屏蔽层(24)位于所述内绝缘层(12)外侧。
4.根据权利要求3所述的一种抗冲击高耐磨电缆,其特征在于:所述内衬层(11)为特氟龙材质,所述内绝缘层(12)为橡胶材质,所述屏蔽层(24)为铜质编织网,所述外绝缘层(13)为PVC材质。
5.根据权利要求1所述的一种抗冲击高耐磨电缆,其特征在于:所述防冲击机构(2)包括筒壳(14)、吸能机构(15)和外护板(16),所述吸能机构(15)均固定在所述筒壳(14)的外壁上,所述外护板(16)均固定在所述吸能机构(15)上。
6.根据权利要求5所述的一种抗冲击高耐磨电缆,其特征在于:外护板(16)为弧形,且贴合在所述外壳层(3)的内壁上,所述外护板(16)之间固定连接有防护绳(17),所述防护绳(17)为钢丝绳。
7.根据权利要求6所述的一种抗冲击高耐磨电缆,其特征在于:所述筒壳(14)内设有加强钢芯(18),所述筒壳(14)的侧壁上设有固定片(19),所述吸能机构(15)包括吸能座(20),吸能弹簧(21)和吸能杆(22),所述吸能座(20)的侧壁上设有弧槽(23),所述吸能座(20)内设有空腔,所述吸能弹簧(21)固定在所述空腔内的底部上,所述吸能杆(22)固定在所述吸能弹簧(21)上,且所述吸能杆(22)延伸至所述吸能座(20)外。
8.权利要求7任一项所述的一种抗冲击高耐磨电缆的加工工艺,其特征在于:S1:在所述导电芯(10)外套设所述内衬层(11),可采用绕包,然后进行包覆内所述绝缘层,然后套设所述屏蔽层(24),包覆所述外绝缘层(13);
S2:使用外部挤压设备将防冲击机构(2)均匀固定在加强钢芯(18)上,即通过挤压所述固定片(19)将筒壳(14)固定;
S3:将所述主导线(1)放置在所述筒壳(14)内壁上的所述弧槽(23)内,可用粘胶辅助固定,然后使用橡胶对所述主导线(1)和所述防冲击机构(2)填充处理,将外形定型为圆柱形,然后在填充物外挤包铝制壳;
S4:向铝制壳外挤包缓冲层(6),然后埋设加强绳(7),然后绕覆隔热层(5),以及挤包防护层(4),然后在防护层(4)上开设安装槽,然后设置耐磨环(8)即可。
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