EP0797219A1 - Coaxial cable manufacturing process - Google Patents

Coaxial cable manufacturing process Download PDF

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Publication number
EP0797219A1
EP0797219A1 EP97104224A EP97104224A EP0797219A1 EP 0797219 A1 EP0797219 A1 EP 0797219A1 EP 97104224 A EP97104224 A EP 97104224A EP 97104224 A EP97104224 A EP 97104224A EP 0797219 A1 EP0797219 A1 EP 0797219A1
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EP
European Patent Office
Prior art keywords
core
strip
tube
layer
copper
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.)
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Application number
EP97104224A
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German (de)
French (fr)
Inventor
Bruno Buluschek
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Kertscher E SA
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Kertscher E SA
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Publication date
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Publication of EP0797219A1 publication Critical patent/EP0797219A1/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
    • H01B13/2613—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by longitudinal lapping
    • H01B13/2633—Bending and welding of a metallic screen
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/016—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing co-axial cables
    • H01B13/0162—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing co-axial cables of the central conductor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49123—Co-axial cable
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/53—Means to assemble or disassemble
    • Y10T29/53126—Means to place sheath on running-length core

Definitions

  • the present invention relates to a method of manufacturing coaxial cables, and more specifically to a method of making a core for coaxial cable.
  • Coaxial cables have been replaced by optical fibers in the field of long-distance transmissions, but their use in many other fields is constantly increasing.
  • Coaxial cables which are used in particular for data transmission, generally comprise a conductive core covered with a layer of dielectric material, a polymer in the form of foam, the outer surface of the dielectric being covered with an outer conductive layer. , which can be made from a welded metal strip, itself covered with a film of insulating material.
  • the present invention results from research aimed at reducing the cost price of the conductive core.
  • a core of solid copper wire is only used for cores of small diameter, namely less than 2 mm.
  • the copper tubes are obtained by drawing from copper ingots. However, their price is relatively high because of the complexity of their production process. On the other hand, they are delivered in relatively short lengths, because of their method of manufacture and also the size of the coils loaded with tube. It is therefore necessary, during the manufacture of coaxial cable, to make end-to-end connections which require great care not to reduce the electrical performance of the coaxial cable obtained. Furthermore, the use of copper tubes makes the cores thus produced heavy and little, flexible, and this because of the relatively large thickness of the walls of the tubes imposed by the mechanical stresses that the tubes must support during their manufacture.
  • the object of the present invention is to provide a method of manufacturing a coaxial cable core which is less complex than current techniques, and makes it possible to obtain lower cost prices.
  • the use of techniques for forming tubes from a strip of an electrically conductive material makes it possible to obtain, without excessive difficulty, tubular cores whose thickness is relatively small. with respect to the diameter of the tube in comparison with tubular cores of the same diameter and obtained by drawing from the prior art.
  • the method according to the invention allows, among other advantages, therefore to produce lighter, more flexible and less costly cores than those produced according to the techniques of the prior art.
  • the method comprises, after the welding step, a step of calibrating the tube obtained, during which the tube is given a section with a perfectly circular outer contour.
  • the calibration thus makes it possible to obtain a core with a cylindrical outer contour, which makes it possible, during the subsequent stages of making the coaxial cable, to obtain thicknesses of insulating layer which certainly have the minimum value required.
  • the method comprises, after the step of calibrating the core, a step of treating the external surface of the tube intended to promote the adhesion of said electrically insulating layer.
  • the treatment of the external surface can include a chemical treatment, by passing the tube through a container filled with an appropriate bath. It is more advantageous to provide that this step involves the deposition, on the exterior surface, of a promoter product. adhesion, this deposit being, according to an advantageous embodiment, produced by passing the tube through a container containing said product in the pasty state.
  • the method of the invention further comprises depositing a layer of insulating material on the previously formed core, this layer being optionally provided with a protective skin.
  • the insulating material is a foam
  • the deposition is carried out by passing the tube through a container containing the foam in formation.
  • an intermediate product is obtained in the manufacture of the coaxial cable.
  • This product can be completed to form a coaxial cable using other facilities. It supports particularly well the manipulations in the case where the layer of insulating material is covered with a protective skin.
  • the process just described can, of course, be carried out batchwise, by making successive lengths of coaxial cable, however it is it is preferable to provide that it is produced continuously by using a very long continuous strip to constitute the core, the tube in formation being driven through a forming station and welding by drive means arranged after said forming station. and welding, these drive means being arranged after a calibration station if a calibration is carried out, and before a surface treatment station, if such a treatment is carried out.
  • This way of operating keeps the core in formation under tension during forming and sizing, which provides better quality, and in addition it prevents the layer having undergone the surface treatment from being damaged by the means of drive, which could adversely affect the adhesion of the insulating material.
  • the coaxial cable shown in FIG. 1 comprises a core 1, which is here made of copper, but which could be made of steel coated on the outside with copper, aluminum, aluminum coated on the outside with copper or the like.
  • the outer contour of the section of the core 1 is perfectly circular, but this section shows that it was obtained from a continuous strip, made of an electrically conductive material, curved until having in section the shape d 'a closed curve, edges 2 and 3 being contiguous.
  • a zone 4 which has been melted with the laser, ensures the junction between the edges 3 and 4. It will be noted here that it is well known that a zone thus melted has a metallographic structure different from that of the unmelted parts, and is therefore easily discernible for the specialist.
  • a layer 5 of adhesion promoting product On the outer surface of the core 1 is a layer 5 of adhesion promoting product, of substantially constant thickness, which is in fact of the order of 0.04 to 0.08 mm, with a low eccentricity.
  • the core coated with the adhesion promoting product 5 is surrounded by a continuous and relatively thick layer of insulation material, here constituted by polyethylene foam.
  • the insulation layer 6 is itself covered with a thin protective skin 7, which is in contact with an external conductor 8, formed like the core 1, from a strip of aluminum, of aluminum covered copper or copper folded back on itself and laser welded.
  • the core for the external conductor, it is the internal surface which must meet strict conditions of reduced cylindricity and eccentricity, at least over most of its periphery, while the shape of its outer surface is of less importance.
  • the radial thickness E of the insulating layer preferably says to be as constant as possible over the major part of the periphery of the cable, this thickness possibly locally being greater than the value E, but never less.
  • Figures 2a, 2b and 3a, 3b relate to an installation intended to operate continuously, the products moving from left to right in these two figures.
  • Reels 11 are each intended to carry a coil 12 of metallic strip of copper, aluminum, copper-clad aluminum or copper-clad steel, wound flat.
  • the reference 13 designates a laser welding station designed to connect together successive lengths of strips extracted from one of the coils 12. It will be observed here, that the connection of two flat strips between them is much easier than the connection of two tubes.
  • Reference 14 designates a tape accumulator, intended to prevent jolts or interruptions in the supply of the rest of the installation.
  • Reference 15 designates the forming and welding installation.
  • This installation comprises a series of rollers 16 acting mainly in the vertical direction, followed by a second series of rollers 17 acting in a horizontal or oblique direction, according to a well known technique.
  • a laser welding station 18 follows these two series of rollers, and is itself followed by a new series of rollers 19 acting in the vertical direction.
  • a calibration tool 20 is arranged so as to give the tube a cylindrical outer surface, of section as perfectly circular as possible.
  • Reference 21 designates a gauge intended to control the diameter of the tube thus formed.
  • a trainer 22 follows the diameter controller.
  • Reference 23 designates a welding control device, intended to ensure that the welding has been carried out without fault.
  • Reference 24 designates a surface conditioner, which may in particular comprise means for brushing the external surface of the tube.
  • Reference 25 designates an extruder for a thin layer of an adhesion promoter, deposited in the pasty state.
  • the extruder 25 is itself followed by an extruder 26 which is larger in volume, and which is intended to extrude the polyethylene foam.
  • This extruder 26 conventionally contains means for heating the polyethylene, and means for mixing the latter with a foaming gas, here nitrogen.
  • the cooling extruder 26 is immediately followed by a water tank 27 intended for cooling the foam layer 6 and therefore for forming the skin 7.
  • a dryer 28 is followed by a cooling tank 29, which is followed by a second dryer 30. After passing through a diameter gauge 31, the product is driven by a second drive device 32 to be wound on a reel 33 mounted on a reel 34.
  • the coil 33 will be unwound for the installation of the external conductor and the finishing of the coaxial cable.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacturing Of Electric Cables (AREA)

Abstract

The method is for manufacturing a coaxial cable which comprises a core (1) made of copper, copper-coated steel to copper-coated aluminium, since the surface conductivity is most important for high frequency transmissions. The outside section of the core is perfectly circular, but this section is obtained by wrapping a flat sheet of conducting material around the surface, the edges being joined together (2,3). A region (4) is formed where a laser fuses the edges together. The metallurgical structure of this joint region is different from that of the rest of the sheet. The core is surrounded by a thin layer of material (5), between 0.04 and 0.08 mm thick, which helps to ensure a low degree of eccentricity for the core. This is surrounded by a thicker insulation material (6) which may be plastic foam. This is enclosed by a thin protective skin (7) and the outer conductor (8) formed from a material similar to that of the core.

Description

La présente invention est relative à un procédé de fabrication de câbles coaxiaux, et plus précisément à un procédé de confection d'une âme pour câble coaxial.The present invention relates to a method of manufacturing coaxial cables, and more specifically to a method of making a core for coaxial cable.

Les câbles coaxiaux, ont été remplacés par les fibres optiques dans le domaine des transmissions à longue distance, mais leur utilisation dans de nombreux autres domaines est en augmentation constante.Coaxial cables have been replaced by optical fibers in the field of long-distance transmissions, but their use in many other fields is constantly increasing.

Les câbles coaxiaux, qui servent notamment à la, transmission de données, comprennent généralement une âme conductrice recouverte d'une couche d'un matériau diélectrique, un polymère sous forme de mousse, la surface extérieure du diélectrique étant recouverte d'une couche conductrice extérieure, qui peut être réalisée à partir d'une bande métallique soudée, elle-même recouverte d'un film de matériau isolant.Coaxial cables, which are used in particular for data transmission, generally comprise a conductive core covered with a layer of dielectric material, a polymer in the form of foam, the outer surface of the dielectric being covered with an outer conductive layer. , which can be made from a welded metal strip, itself covered with a film of insulating material.

La présente invention résulte de recherches en vue de réduire le prix de revient de l'âme conductrice.The present invention results from research aimed at reducing the cost price of the conductive core.

L'emploi d'une âme en fil de cuivre plein a été réduit au minimum pour diverses raisons, et notamment le coût élevé de ce métal.The use of a solid copper wire core has been minimized for a variety of reasons, including the high cost of this metal.

En pratique une âme en fil de cuivre plein n'est utilisée que pour des âmes de faible diamètre, à savoir inférieur à 2 mm.In practice, a core of solid copper wire is only used for cores of small diameter, namely less than 2 mm.

Pour les âmes ayant des diamètres compris entre 2 mm et 5 mm environ, on la réalise généralement à partir d'un fil d'aluminium plein sur lequel est rapportée une couche de cuivre.For cores with diameters between 2 mm and 5 mm approximately, it is generally produced from a solid aluminum wire on which a layer of copper is attached.

Cette façon d'obtenir l'âme a pour inconvénient que le procédé pour obtenir le revêtement de cuivre sur le fil d'aluminium est complexe et coûteux.This way of obtaining the core has the disadvantage that the process for obtaining the copper coating on the aluminum wire is complex and expensive.

Enfin, pour les âmes ayant des diamètres supérieurs à 5 mm la solution actuelle consiste à utiliser des tubes de cuivre.Finally, for cores with diameters greater than 5 mm the current solution consists in using copper tubes.

Les tubes de cuivre, sont obtenus par étirage à partir de lingots de cuivre. Toutefois, leur prix est relativement élevé à cause de la complexité de leur procédé d'obtention. D'autre part, ils sont livrés en longueurs relativement faibles, à cause de leur mode de fabrication et aussi de l'encombrement des bobines chargées de tube. Il est donc nécessaire, lors de la fabrication de câble coaxial, de procéder à des raccordements bout-à-bout qui exigent un grand soin pour ne pas réduire les performances électriques du câble coaxial obtenu. Par ailleurs, l'utilisation de tubes en cuivre rend les âmes ainsi réalisées lourdes et peu, flexibles, et ceci en raison de l'épaisseur des parois des tubes relativement importante imposée par les contraintes mécaniques que les tubes doivent supporter lors de leur fabrication.The copper tubes are obtained by drawing from copper ingots. However, their price is relatively high because of the complexity of their production process. On the other hand, they are delivered in relatively short lengths, because of their method of manufacture and also the size of the coils loaded with tube. It is therefore necessary, during the manufacture of coaxial cable, to make end-to-end connections which require great care not to reduce the electrical performance of the coaxial cable obtained. Furthermore, the use of copper tubes makes the cores thus produced heavy and little, flexible, and this because of the relatively large thickness of the walls of the tubes imposed by the mechanical stresses that the tubes must support during their manufacture.

La présente invention a pour but de fournir un procédé de fabrication d'âme de câble coaxial qui soit moins complexe que les techniques actuelles, et permette d'obtenir des prix de revient moins élevés.The object of the present invention is to provide a method of manufacturing a coaxial cable core which is less complex than current techniques, and makes it possible to obtain lower cost prices.

Pour obtenir ce résultat, l'invention fournit un procédé de confection d'une âme pour un câble coaxial comprenant une âme tubulaire, dont au moins la surface extérieure est en cuivre ou autre matériau conducteur, une couche isolante électriquement entourant l'âme, et un conducteur extérieur recouvrant la couche isolante et isolé électriquement par rapport à l'âme, ce procédé ayant pour particularité qu'il comprend les étapes suivantes :

  • fournir une bande en un matériau électriquement conducteur,
  • former la bande en un tube, les deux bords de la bande étant sensiblement en contact, et
  • souder ensemble les deux bords de la bande formée en tube, par soudage laser.
To obtain this result, the invention provides a method of making a core for a coaxial cable comprising a tubular core, at least the outer surface of which is made of copper or other conductive material, an electrically insulating layer surrounding the core, and an outer conductor covering the insulating layer and electrically insulated from the core, this process having the particularity that it comprises the following steps:
  • providing a strip of an electrically conductive material,
  • forming the strip into a tube, the two edges of the strip being substantially in contact, and
  • weld together the two edges of the strip formed into a tube, by laser welding.

Ainsi, l'utilisation des techniques de formage de tubes à partir d'une bande en un matériau électriquement conducteur permet d'obtenir sans difficulté excessive des âmes tubulaires dont l'épaisseur est relativement faible par rapport au diamètre du tube en comparaison avec des âmes tubulaires de même diamètre et obtenu par étirage de l'art antérieur. A titre d'exemple, il est possible selon l'invention de réaliser des âmes ayant des épaisseurs de parois aussi faible que 0,2 mm pour un diamètre de l'ordre d'une dizaines de millimètres. Le procédé selon l'invention permet entre autres avantages de réaliser par conséquent des âmes plus légères, plus flexibles et moins coûteuses que celles réalisées selon les techniques de l'art antérieur.Thus, the use of techniques for forming tubes from a strip of an electrically conductive material makes it possible to obtain, without excessive difficulty, tubular cores whose thickness is relatively small. with respect to the diameter of the tube in comparison with tubular cores of the same diameter and obtained by drawing from the prior art. By way of example, it is possible according to the invention to produce cores having wall thicknesses as small as 0.2 mm for a diameter of the order of tens of millimeters. The method according to the invention allows, among other advantages, therefore to produce lighter, more flexible and less costly cores than those produced according to the techniques of the prior art.

L'utilisation d'une bande permet également le raccordement bout à bout de deux bandes consécutives par une simple soudure en ligne, ce qui facilite la production de l'âme en continu.The use of a strip also allows the end-to-end connection of two consecutive strips by a simple in-line welding, which facilitates the production of the core continuously.

De préférence, le procédé comprend après l'étape de soudage, une étape de calibrage du tube obtenu, au cours de laquelle on donne au tube une section à contour extérieur parfaitement circulaire.Preferably, the method comprises, after the welding step, a step of calibrating the tube obtained, during which the tube is given a section with a perfectly circular outer contour.

Le calibrage permet ainsi d'obtenir une âme à contour extérieur cylindrique, ce qui permet, lors des étapes ultérieures de confection du câble coaxial, d'obtenir des épaisseurs de couche isolante ayant à coup sûr la valeur minimale requise.The calibration thus makes it possible to obtain a core with a cylindrical outer contour, which makes it possible, during the subsequent stages of making the coaxial cable, to obtain thicknesses of insulating layer which certainly have the minimum value required.

De préférence également, le procédé comprend après l'étape de calibrage de l'âme , une étape de traitement de la surface extérieure du tube destinée à promouvoir l'adhérence de ladite couche isolante électriquement.Also preferably, the method comprises, after the step of calibrating the core, a step of treating the external surface of the tube intended to promote the adhesion of said electrically insulating layer.

Le fait de prévoir le traitement de la surface extérieure de l'âme après son calibrage permet d'avoir la certitude d'une adhérence de la matière isolante qui sera constante sur toute cette surface, sans risque de décollement ou de formation de bulles, ce qui garantit la haute qualité du produit final.The fact of providing for the treatment of the external surface of the core after its calibration makes it possible to have the certainty of an adhesion of the insulating material which will be constant over this entire surface, without the risk of detachment or of formation of bubbles, this which guarantees the high quality of the final product.

Le traitement de la surface extérieure peut comporter un traitement chimique, par passage du tube à travers un récipient rempli d'un bain approprié. Il est plus avantageux de prévoir que cette étape comporte le dépôt, sur la surface extérieure, d'un produit promoteur d'adhérence, ce dépôt étant, suivant une réalisation intéressante, réalisé par passage du tube à travers un récipient contenant ledit produit à l'état pâteux.The treatment of the external surface can include a chemical treatment, by passing the tube through a container filled with an appropriate bath. It is more advantageous to provide that this step involves the deposition, on the exterior surface, of a promoter product. adhesion, this deposit being, according to an advantageous embodiment, produced by passing the tube through a container containing said product in the pasty state.

Le procédé de l'invention comprend en outre le dépôt d'une couche de matière isolante sur l'âme formée antérieurement, cette couche étant éventuellement pourvue d'une peau protectrice.The method of the invention further comprises depositing a layer of insulating material on the previously formed core, this layer being optionally provided with a protective skin.

Avantageusement, la matière isolante est une mousse, et le dépôt est réalisé par passage du tube dans un récipient contenant la mousse en formation.Advantageously, the insulating material is a foam, and the deposition is carried out by passing the tube through a container containing the foam in formation.

Quand le procédé contient l'étape qu'on vient de décrire, on obtient un produit intermédiaire dans la, fabrication du câble coaxial. Ce produit peut être complété pour former un câble coaxial à l'aide d'autres installations. Il supporte particulièrement bien les manipulations dans le cas où la couche de matière isolante est recouverte d'une peau protectrice.When the process contains the step just described, an intermediate product is obtained in the manufacture of the coaxial cable. This product can be completed to form a coaxial cable using other facilities. It supports particularly well the manipulations in the case where the layer of insulating material is covered with a protective skin.

On peut également prévoir d'aller plus loin dans la confection du câble coaxial, et prévoir que le procédé comprend en outre une étape de mise en place d'un conducteur extérieur entourant la couche de matière isolante pour constituer un câble coaxial.We can also plan to go further in the making of the coaxial cable, and provide that the method further comprises a step of placing an external conductor surrounding the layer of insulating material to form a coaxial cable.

Avantageusement, l'étape de mise en place du conducteur extérieur comprend elle-même les étapes suivantes :

  • fournir une bande supplémentaire de matière conductrice,
  • former cette bande en un tube entourant ladite âme recouverte de ladite matière isolante, éventuellement pourvue d'une peau protectrice,
  • souder ensemble les deux bords de la bande supplémentaire formée en tube, par soudage laser, et
  • éventuellement recouvrir ensuite la deuxième bande formée en tube soudé avec une enveloppe protectrice.
Advantageously, the step of fitting the external conductor itself comprises the following steps:
  • provide an additional strip of conductive material,
  • forming this strip into a tube surrounding said core covered with said insulating material, possibly provided with a protective skin,
  • weld together the two edges of the additional strip formed into a tube, by laser welding, and
  • then possibly cover the second strip formed in a welded tube with a protective covering.

On a ainsi confectionné un tube coaxial complet.A complete coaxial tube was thus made.

Le procédé qu'on vient de décrire peut, bien évidemment être réalisé en discontinu, par confection de longueurs successives de câble coaxial cependant il est préférable de prévoir qu'il est réalisé en continu en utilisant une bande continue de grande longueur pour constituer l'âme, le tube en formation étant entraîné à travers un poste de formage et soudage par des moyens d'entraînement disposés après ledit poste de formage et soudage, ces moyens d'entraînement étant disposés après un poste de calibrage s'il est procédé à un calibrage, et avant un poste de traitement de surface, s'il est procédé à un tel traitement.The process just described can, of course, be carried out batchwise, by making successive lengths of coaxial cable, however it is it is preferable to provide that it is produced continuously by using a very long continuous strip to constitute the core, the tube in formation being driven through a forming station and welding by drive means arranged after said forming station. and welding, these drive means being arranged after a calibration station if a calibration is carried out, and before a surface treatment station, if such a treatment is carried out.

Cette manière d'opérer permet de maintenir l'âme en formation sous tension pendant le formage et le calibrage, ce qui procure une meilleure qualité, et en plus elle, évite que la couche ayant subi le traitement de surface soit endommagée par les moyens d'entraînement, ce qui pourrait nuire à l'adhérence de la matière isolante.This way of operating keeps the core in formation under tension during forming and sizing, which provides better quality, and in addition it prevents the layer having undergone the surface treatment from being damaged by the means of drive, which could adversely affect the adhesion of the insulating material.

Le procédé de l'invention va être décrit de façon plus détaillée à l'aide d'un exemple pratique illustré avec les dessins, parmi lesquels :

  • la figure 1, est une vue en coupe transversale d'un exemple de câble coaxial obtenu selon le procédé de l'invention, et
  • les figures 2a, 2b et 3a, 3b sont des vues en élévation et de dessus d'une installation mettant en oeuvre le procédé de l'invention pour la production d'un produit intermédiaire consistant en une âme recouverte d'une couche de matière isolante, les étapes suivantes de la confection du câble coaxial fini, qui sont connues en elles-mêmes, n'étant pas représentées.
The process of the invention will be described in more detail using a practical example illustrated with the drawings, among which:
  • FIG. 1 is a cross-sectional view of an example of a coaxial cable obtained according to the method of the invention, and
  • FIGS. 2a, 2b and 3a, 3b are views in elevation and from above of an installation implementing the method of the invention for the production of an intermediate product consisting of a core covered with a layer of insulating material , the following stages of making the finished coaxial cable, which are known in themselves, not being shown.

Le câble coaxial représenté à la figure 1 comprend une âme 1, qui est ici en cuivre, mais qui pourrait être en acier revêtu extérieurement de cuivre, en aluminium, en aluminium revêtu extérieurement de cuivre ou analogue.The coaxial cable shown in FIG. 1 comprises a core 1, which is here made of copper, but which could be made of steel coated on the outside with copper, aluminum, aluminum coated on the outside with copper or the like.

On notera à ce propos que c'est la conductivité électrique de la surface extérieure de l'âme qui est prépondérante dans le transport de signaux à haute fréquence via les câbles coaxiaux et lorsque l'on utilise une bande métallique revêtue de cuivre, la face constituée de cuivre se trouve à l'extérieur.It should be noted in this connection that it is the electrical conductivity of the outer surface of the core which is predominant in the transport of high frequency signals via coaxial cables and when using a metal strip coated with copper, the face made of copper is found on the outside.

Le contour extérieur de la section de l'âme 1 est parfaitement circulaire, mais cette section montre qu'elle a été obtenue à partir d'une bande continue, réalisée en un matériau électriquement conducteur, courbée jusqu'à avoir en section la forme d'une courbe fermée, les bords 2 et 3 étant jointifs. Une zone 4, qui a été fondue au laser assure la jonction entre les bords 3 et 4. On notera ici qu'il est bien connu qu'une zone ainsi fondue présente une structure métallographique différente de celle des parties non fondues, et est donc facilement discernable pour le spécialiste.The outer contour of the section of the core 1 is perfectly circular, but this section shows that it was obtained from a continuous strip, made of an electrically conductive material, curved until having in section the shape d 'a closed curve, edges 2 and 3 being contiguous. A zone 4, which has been melted with the laser, ensures the junction between the edges 3 and 4. It will be noted here that it is well known that a zone thus melted has a metallographic structure different from that of the unmelted parts, and is therefore easily discernible for the specialist.

Sur la surface extérieure de l'âme 1 se trouve une, couche 5 de produit promoteur d'adhérence, d'épaisseur sensiblement constante, et qui est en fait de l'ordre de 0,04 à 0,08 mm, avec une faible excentricité.On the outer surface of the core 1 is a layer 5 of adhesion promoting product, of substantially constant thickness, which is in fact of the order of 0.04 to 0.08 mm, with a low eccentricity.

L'âme revêtue du produit promoteur d'adhérence 5 est entourée d'une couche continue et relativement épaisse de matière d'isolation, ici constituée par de la mousse de polyéthylène.The core coated with the adhesion promoting product 5 is surrounded by a continuous and relatively thick layer of insulation material, here constituted by polyethylene foam.

La couche d'isolation 6 est elle-même recouverte d'une peau protectrice mince 7, laquelle est en contact avec un conducteur extérieur 8, formé comme l'âme 1, à partir d'une bande d'aluminium, d'aluminium recouvert de cuivre ou de cuivre repliée sur elle-même et soudée au laser.The insulation layer 6 is itself covered with a thin protective skin 7, which is in contact with an external conductor 8, formed like the core 1, from a strip of aluminum, of aluminum covered copper or copper folded back on itself and laser welded.

On observera cependant une différence entre l'âme et le conducteur extérieur: pour le conducteur extérieur, c'est la surface intérieure qui doit répondre à des conditions strictes de cylindricité et d'excentricité réduites, tout au moins sur la plus grande partie de son pourtour, alors que la forme de sa surface extérieure est de moindre importance.We will however observe a difference between the core and the external conductor: for the external conductor, it is the internal surface which must meet strict conditions of reduced cylindricity and eccentricity, at least over most of its periphery, while the shape of its outer surface is of less importance.

En effet, l'épaisseur radiale E de la couche isolante dit de préférence être la plus constante possible sur la majeure partie de la périphérie du câble, cette épaisseur pouvant localement être supérieure à la valeur E, mais jamais inférieure.Indeed, the radial thickness E of the insulating layer preferably says to be as constant as possible over the major part of the periphery of the cable, this thickness possibly locally being greater than the value E, but never less.

Une enveloppe protectrice 9, en matière plastique appropriée, entoure et protège le conducteur extérieur 8.A protective envelope 9, made of an appropriate plastic material, surrounds and protects the external conductor 8.

Les figures 2a, 2b et 3a, 3b sont relatives à une installation prévue pour fonctionner en continu, les produits se déplaçant de la gauche vers la droite sur ces deux figures.Figures 2a, 2b and 3a, 3b relate to an installation intended to operate continuously, the products moving from left to right in these two figures.

Des dévidoirs 11 sont destinés à porter chacun une bobine 12 de bande métallique en cuivre, en aluminium, en aluminium cuivré ou en acier cuivré, enroulées à plat.Reels 11 are each intended to carry a coil 12 of metallic strip of copper, aluminum, copper-clad aluminum or copper-clad steel, wound flat.

La référence 13 désigne un poste de soudage au laser conçu pour raccorder entre elles des longueurs successives de bandes extraites d'une des bobines 12. On observera ici, que le raccordement de deux bandes plates entre elles est bien plus facile que le raccordement de deux tubes.The reference 13 designates a laser welding station designed to connect together successive lengths of strips extracted from one of the coils 12. It will be observed here, that the connection of two flat strips between them is much easier than the connection of two tubes.

La référence 14 désigne un accumulateur de bande, destiné à empêcher les à-coups ou les interruptions dans l'alimentation de la suite de l'installation.Reference 14 designates a tape accumulator, intended to prevent jolts or interruptions in the supply of the rest of the installation.

La référence 15 désigne l'installation de formage et soudage.Reference 15 designates the forming and welding installation.

Cette installation comprend une série de galets 16 agissant principalement dans le sens vertical, suivie d'une deuxième série de galets 17 agissant en direction horizontale ou oblique, suivant une technique bien connue.This installation comprises a series of rollers 16 acting mainly in the vertical direction, followed by a second series of rollers 17 acting in a horizontal or oblique direction, according to a well known technique.

Un poste de soudage laser 18 fait suite à ces deux séries de galets, et il est lui-même suivi d'une nouvelle série de galets 19 agissant dans le sens vertical.A laser welding station 18 follows these two series of rollers, and is itself followed by a new series of rollers 19 acting in the vertical direction.

Au-delà du poste de formage et soudage 15, un outil de calibrage 20 est disposé de façon à donner au tube une surface extérieure cylindrique, à section aussi parfaitement circulaire que possible.Beyond the forming and welding station 15, a calibration tool 20 is arranged so as to give the tube a cylindrical outer surface, of section as perfectly circular as possible.

La référence 21 désigne une jauge destinée à contrôler le diamètre du tube ainsi formé. Un entraîneur 22 fait suite au contrôleur de diamètre.Reference 21 designates a gauge intended to control the diameter of the tube thus formed. A trainer 22 follows the diameter controller.

La référence 23 désigne un appareil de contrôle de la soudure, destiné à assurer que celle-ci a été exécutée sans défaut.Reference 23 designates a welding control device, intended to ensure that the welding has been carried out without fault.

La référence 24 désigne un conditionneur de surface, qui peut comporter en particulier des moyens de brossage de la surface extérieure du tube.Reference 24 designates a surface conditioner, which may in particular comprise means for brushing the external surface of the tube.

La référence 25 désigne une extrudeuse pour une couche mince d'un promoteur d'adhérence, déposé à l'état pâteux. L'extrudeuse 25 est elle-même suivie d'une extrudeuse 26 plus important en volume, et qui est destinée à extruder la mousse de polyéthylène. Cette extrudeuse 26 de façon classique, contient des moyens de chauffage du polyéthylène, et des moyens pour mélanger celui-ci à un gaz de moussage, ici de l'azote.Reference 25 designates an extruder for a thin layer of an adhesion promoter, deposited in the pasty state. The extruder 25 is itself followed by an extruder 26 which is larger in volume, and which is intended to extrude the polyethylene foam. This extruder 26 conventionally contains means for heating the polyethylene, and means for mixing the latter with a foaming gas, here nitrogen.

L'extrudeuse de refroidissement 26 est suivie, immédiatement d'un bac à eau 27 destiné au refroidissement de la couche de mousse 6 et donc à la formation de la peau 7.The cooling extruder 26 is immediately followed by a water tank 27 intended for cooling the foam layer 6 and therefore for forming the skin 7.

Un séchoir 28 est suivi d'un bac de refroidissement 29, lequel est suivi d'un deuxième séchoir 30. Après passage dans un jauge de diamètre 31, le produit est entraîné par un deuxième dispositif d'entraînement 32 pour être enroulé sur une bobine 33 montée sur un enrouleur 34.A dryer 28 is followed by a cooling tank 29, which is followed by a second dryer 30. After passing through a diameter gauge 31, the product is driven by a second drive device 32 to be wound on a reel 33 mounted on a reel 34.

Dans une installation différente, la bobine 33 sera dévidée pour la mise en place du conducteur extérieur et la finition du câble coaxial.In a different installation, the coil 33 will be unwound for the installation of the external conductor and the finishing of the coaxial cable.

Bien entendu, il serait possible de supprimer la bobine 33 et l'enrouleur 34, et de prévoir une installation de mise en place du conducteur extérieur et de l'enveloppe protectrice directement à la suite de l'installation qu'on vient de décrire.Of course, it would be possible to eliminate the coil 33 and the reel 34, and to provide an installation installation of the external conductor and the protective casing directly following the installation which has just been described.

Claims (12)

Procédé de confection d'une âme pour un câble coaxial comprenant une âme tubulaire (1), dont au moins la surface extérieure est en cuivre ou autre matériau conducteur, une couche de matière isolante électriquement (6) entourant l'âme, et un conducteur extérieur (8) recouvrant la couche de matière isolante et isolé électriquement par rapport à l'âme,
caractérisé en ce qu'il comprend les étapes suivantes : - fournir une bande en un matériau électriquement conducteur, - former la bande en un tube, les deux bords de la bande étant sensiblement en contact, et - souder ensemble les deux bords de la bande formée en tube, par soudage laser, pour constituer l'âme (1). Method of manufacturing a core for a coaxial cable comprising a tubular core (1), at least the outer surface of which is made of copper or other conductive material, a layer of electrically insulating material (6) surrounding the core, and a conductor outside (8) covering the layer of insulating material and electrically insulated from the core,
characterized in that it comprises the following stages: - supply a strip of electrically conductive material, forming the strip into a tube, the two edges of the strip being substantially in contact, and - weld together the two edges of the strip formed into a tube, by laser welding, to form the core (1). Procédé selon la revendication 1, caractérisé en ce qu'il comprend après l'étape de soudage, une étape de calibrage de l'âme tubulaire obtenue (1), au cours de laquelle on donne à celle-ci une section à contour extérieur circulaire.Method according to claim 1, characterized in that it comprises, after the welding step, a step of calibrating the tubular core obtained (1), during which it is given a section with a circular external contour . Procédé selon la revendication 1 ou 2, caractérisé en ce qu'il comprend, après l'étape de calibrage de l'âme, une étape de traitement de la surface extérieure de l'âme destinée à promouvoir l'adhérence de ladite couche isolante électriquement (6).Method according to claim 1 or 2, characterized in that it comprises, after the step of calibrating the core, a step of treating the external surface of the core intended to promote the adhesion of said electrically insulating layer (6). Procédé selon la revendication 3, caractérisé en ce que ladite étape de traitement de la surface extérieure comporte le dépôt d'une couche (5) d'un produit promoteur d'adhérence.A method according to claim 3, characterized in that said step of treating the outer surface comprises depositing a layer (5) of an adhesion promoting product. Procédé selon la revendication 4, caractérisé en ce que le dépôt du produit promoteur d'adhérence est réalisé par passage du tube à travers le récipient contenant ledit produit à l'état pâteuxProcess according to Claim 4, characterized in that the deposition of the adhesion promoting product is carried out by passing the tube through the container containing the said product in a pasty state. Procédé selon l'une des revendications 1 à 5, caractérisé en ce qu'il comprend en outre le dépôt d'une couche de matière isolante (6) sur l'âme (1) formée antérieurement, cette couche étant éventuellement pourvue d'une peau protectrice (7).Method according to one of claims 1 to 5, characterized in that it further comprises depositing a layer of insulating material (6) on the core (1) formed previously, this layer being optionally provided with a protective skin (7). Procédé selon la revendication 6, caractérisé en ce que la matière isolante est une mousse, et que le dépôt est réalisé par passage de l'âme (1) dans un récipient contenant la mousse en formation.A method according to claim 6, characterized in that the insulating material is a foam, and that the deposition is carried out by passing the core (1) through a container containing the foam in formation. Procédé selon l'une des revendications 6 ou 7, caractérisé en ce qu'il comprend en outre une étape de mise en place d'un conducteur extérieur (8) entourant la couche de matière isolante (6) pour constituer un câble coaxial.Method according to one of claims 6 or 7, characterized in that it further comprises a step of placing an external conductor (8) surrounding the layer of insulating material (6) to form a coaxial cable. Procédé selon la revendication 8, caractérisé en, ce que l'étape de mise en place du conducteur extérieur comprend elle-même les étapes suivantes : - fournir une bande supplémentaire de matière conductrice, - former cette bande en un tube entourant ladite âme recouverte de ladite matière isolante, éventuellement pourvue d'une peau protectrice, - souder ensemble les deux bords de la bande supplémentaire formée en tube, par soudage laser pour constituer le conducteur extérieur (8), et - éventuellement recouvrir ensuite le conducteur extérieur (8) en tube soudé avec une enveloppe protectrice (9). Method according to claim 8, characterized in that the step of placing the external conductor itself comprises the following steps: - provide an additional strip of conductive material, form this strip into a tube surrounding said core covered with said insulating material, possibly provided with a protective skin, - weld together the two edges of the additional strip formed into a tube, by laser welding to form the outer conductor (8), and - possibly then cover the external conductor (8) in a welded tube with a protective covering (9). Procédé selon l'une des revendications 1 à 9, caractérisé en ce qu'il est réalisé en continu en utilisant une bande continue de grande longueur pour constituer l'âme (1), le tube en formation étant entraîné à travers un poste de formage et soudage (15) par des moyens d'entraînement (22) disposés après ledit poste de formage et soudage, ces moyens d'entraînement étant disposés après un poste de calibrage s'il est procédé à un calibrage, et avant un poste de traitement de surface (24), s'il est procédé à un tel traitement.Method according to one of claims 1 to 9, characterized in that it is carried out continuously using a continuous strip of great length to constitute the core (1), the tube in formation being driven through a forming station and welding (15) by drive means (22) arranged after said forming and welding station, these drive means being arranged after a calibration station if a calibration is carried out, and before a treatment station surface (24), if such treatment is carried out. Procédé selon l'une quelconque des revendications 1 à 10, caractérisé en ce que la bande formant l'âme comprend une bande d'aluminium revêtue de cuivre et en ce que la face revêtue de cuivre est à l'extérieur du tube.Method according to any one of Claims 1 to 10, characterized in that the strip forming the core includes a strip of aluminum coated with copper and in that the face coated with copper is outside the tube. Câble coaxial obtenu selon l'une des revendications 8 ou 9.Coaxial cable obtained according to one of claims 8 or 9.
EP97104224A 1996-03-21 1997-03-13 Coaxial cable manufacturing process Withdrawn EP0797219A1 (en)

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FR9603526A FR2746539B1 (en) 1996-03-21 1996-03-21 METHOD FOR MANUFACTURING COAXIAL CABLES
FR9603526 1996-03-21

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US5946798A (en) 1999-09-07
FR2746539B1 (en) 1998-05-22
FR2746539A1 (en) 1997-09-26
JPH1069826A (en) 1998-03-10

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