EP2207924B1 - Braided rope of synthetic fibers with electrical conductor included therein - Google Patents

Abstract

The invention is directed to a braided chemical fibre cable in which at least one electric conductor is contained, in which the cable is thermally stretched together with the conductor contained therein.

Description

The invention relates to a braided plastic fiber rope arranged around at least one electrical conductor and to a method for producing such a cable.

To a pull rope with at least one integrated electric cable, for example for data transmission or power supply, considerable requirements in terms of mechanical, chemical and electrical properties are often required, such as minimum weight, maximum breaking strength, minimum torsional susceptibility, minimal elongation, buoyancy, resistance to bending load, at least two-core electrical connection for data transmission and power supply and others.

Significant problems are that a braided cable exerts considerable compressive forces on a centrally coaxial conductor when subjected to tensile stress, and that an electrical conductor is exposed to the risk of tearing when the load-carrying cable is subjected to expansion during operation.

From the CH 340430 a pull cable with an electrical cable is known in which a laid in the cable core single or multi-core power cable is surrounded by a flexible and pressure-resistant tube over the entire length and is thus protected against the pressure stresses mentioned. However, the protective tube does not provide protection against the said risk of tearing the conductor due to the rope elongation.

US 5,749,214 describes a braided plastic rope in whose plastic material conductive particles can be embedded.

US 3,153,696 discloses a method of stretching a steel wire reinforced electrical cable at elevated temperature.

US 5,182,779 describes a system for monitoring stresses and strains in ropes by means of a fiber optic incorporated in the rope structure.

The object of the invention is to provide a braided synthetic fiber rope, which is arranged around at least one electrical conductor around, in which the said disadvantages no longer exist, so that the conductor both against the effects of elongation and the compressive stress of the Rope is protected.

According to the invention, this object is achieved in a braided synthetic fiber rope, which is arranged around at least one electrical conductor around , by the measure that the synthetic fiber tension cable is thermally stretched together with the recorded therein conductor.

Experiments have shown that due to the particular stress situation during the thermal stretching occurs with a permanent deformation of the rope and possibly also the conductor associated intimate positive connection of the two elements, i. the cable adapts to the outer contour of the conductor, which is simultaneously compressed by the occurring inwardly directed compression forces, so that in a subsequent operational tensile load of the rope, the risk of deterioration of the conductor by the externally applied compressive forces and the risk of tearing the conductor can be significantly reduced or even practically eliminated completely.

An expedient embodiment is characterized in that the conductor is braided or wound around a core. By this measure, the head receives a stretch reserve, so that there is practically no risk of tearing.

It may be provided that a cable is accommodated in the synthetic fiber pulling cable, comprising an insulated cylindrical core, an insulating, compressible leveling layer surrounding the core, a braided or coiled conductor arranged on the leveling layer, and an insulating jacket layer surrounding the conductor , The arrangement of a compressible leveling layer further reduces the effects of the compressive forces of the rope. The leveling layer may be compliant or elastically compressible, for example in the form of a foam layer.

It can further be provided that a further braided or coiled conductor is arranged on the cladding layer, which is surrounded by a further insulating cladding layer. The thus formed two-wire electrical structure offers advantages for data transmission and power supply.

Between the conductor and the cladding layer, a protective film made of plastic may be arranged, in particular made of PTFE, and optionally in a corresponding manner, a further protective film between the further conductor and the further cladding layer. These films serve as a security, if the insulation capacity of one of the coats is affected by the stretching process.

The leveling layer may be made of foamed or unfoamed plastic, such as a thermoplastic elastomer or a combination of an elastomer and a thermoplastic (two-phase system).

It can be provided that at least one jacket layer consists of an extruded plastic, in particular a thermoplastic or a thermoplastic elastomer. Appropriately, it is provided that the core has a carrier element in the form of a monofilament and an extruded core layer.

The synthetic fiber traction rope containing the at least one conductor can be stretched at a temperature between 60 ° C and 200 ° C, in particular at 90 ° C to 130 ° C.

It is expedient that the synthetic fiber tension rope is subjected to a stretching force which is between 1% and 50% and in particular 20% to 30% of the tensile strength of the synthetic fiber rope. The manmade tow may be subjected to a draw ratio of 3%, 5%, 7%, 9%, 10%, 15% or more together with the conductor or cable received therein, the draw ratio being the increase in length of the drawn tow rope to the initial length, means.

The object of the invention is further achieved by a method for producing a braided synthetic fiber rope with an electrical conductor received therein, comprising the steps of: a) providing the electrical conductor, b) braiding the synthetic fiber rope around the conductor, and c) thermal stretching of the synthetic fiber pull rope containing the conductor.

Step a) may comprise the steps of: a1) providing an insulating core, a2) extruding a compressive layer surrounding the core around the core, a3) placing a braided or coiled electrical conductor on the leveling layer, a4) extruding a conductor surrounding the conductor insulating jacket layer around the conductor, in particular consisting of a thermoplastic elastomer.

Step b) includes a braided (eg, braided) synthetic fiber pull rope which may optionally be braided and / or coated with a protective sheath and comprise 3, 4, 6, 8, 12, 16, 20, 24, 32, or 48 strands can.

It is preferably provided that the synthetic fiber tension rope at a temperature between 60 ° C and 200 ° C, in particular 90 ° C to 130 ° C, is stretched. The synthetic fiber tensioning cable is preferably awakened at a stretching ratio as indicated above.

In a further development of the invention, it can be provided that the following steps are carried out in step a) :-) arranging a further braided or coiled conductor on the jacket layer, and extruding a further insulating layer surrounding the further conductor around the further conductor , in particular consisting of a thermoplastic elastomer.

Between the conductor and the cladding layer, a protective film made of plastic, in particular of PTFE, can be arranged, in particular by banding or wrapping.

In a corresponding manner it can be provided that a further protective film is arranged between the further conductor and the further jacket layer. The core can be made by extruding a core layer onto a cylindrical support member.

It is preferably provided that the leveling layer of foamed or foamable plastic is extruded.

The invention preferably provides that the man-made tow rope is stretched at a stretching force of between 1% and 50% and in particular 20% to 30% of the tensile strength of the manmade tow rope.

The conductor may be braided and have a braid angle of 35 ° to 55 °, in particular 45 °.

The conductor may have a coverage of 70% to 90%, in particular 80%.

It can be provided that the further conductor is braided and has a braid angle of 30 ° to 50 °, in particular 40 °.

The further conductor can have a coverage of 50% to 80%, in particular 65%.

In a preferred embodiment of the invention can be provided that a Aufspreizkörper is arranged with rounded outer contour within the rope at a Kabelausführungsstelle the rope, which has a central Durchführungsöfnung, from which an outwardly opening execution opening goes off, wherein the at least one electrical conductor through the passage opening into the expansion body and out through the execution opening out of this and through the spread ropes to the outside. This measure ensures a lead out of the conductor from the rope at any point, without the risk of crushing or shearing of the conductor is when the rope is subjected to a tensile load.

It can be provided that the expansion body has an at least partially hollow, spindle-shaped cross section in a longitudinal section plane containing a longitudinal axis of the rope. It is preferably provided that the execution opening is directed obliquely axially-radially outward. In addition, a protective sleeve can be arranged in the execution opening.

Conveniently, the expansion body is secured positionally in the cable.

• Fig. 1 eine erste Ausführungsform eines Kabels zur Aufnahme in einem geflochtenen Kunststoffseil zeigt,
• Fig. 2 eine Querschnittsansicht einer zweiten Ausführungsform ähnlich Fig. 1 zeigt, und
• Fig. 3 und 4 eine Kabelein- bzw. -ausführung mit einem abgerundeteten starren Aufspreizkörper zeigen.

Further advantages and features of the invention will become apparent from the following description of exemplary embodiments, reference being made to a drawing in which

• Fig. 1 shows a first embodiment of a cable for receiving in a braided plastic rope,
• Fig. 2 a cross-sectional view of a second embodiment similar Fig. 1 shows, and
• 3 and 4 show a Kabelein- or -ausführung with a rounded rigid Aufspreizkörper.

Fig. 1 shows in a cross-sectional view of the structure of a cable 1 for coaxial arrangement within a merely indicated, braided plastic rope 20, which is to stretch thermally together with the cable received therein.

An insulating cylindrical core of the cable 1 comprises a support element 2 consisting of a PA monofilament having a diameter of about 0.5 mm, on which a hard core layer 4 of PP having an outer diameter of about 1.6 mm is extruded.

Around the core thus formed is extruded an insulating, compressible, compressible leveling layer 6, which in the illustrated example may have an outer diameter of about 2.2 mm +/- 0.1 mm and may consist of foamed LD-PE. Alternatively, the leveling layer may be made of a thermoplastic elastomer, such as PE, PP, PVC, or the like combined with non-thermoplastic portions, such as butadiene components. Also, (such as with beta radiation) crosslinked plastic materials, e.g. PETE materials, used to achieve high heat resistance, as well as fluorine polymers.

Coaxially around the leveling layer and the core located therein, a (first) conductor 8 is arranged, which has an outer diameter of about 2.8 mm and may be formed as a braid. For example, 6 x 7 individual strands of galvanized copper having a single cross sectional area of 0.15 mm may be provided, giving a total cross section of 42 x 0.15 mm ² = 0.75 mm ² .

Preferably, the slope of the first conductor is 8 mm, which corresponds to a braid angle of 45 °. The optimal coverage is 80%.

To the first conductor 8 is concentrically surrounding this enclosing, insulating (first) sheath layer 10 having an outer diameter of about 3.6 mm, which is extruded in particular as a tube. The first cladding layer 10 may be made of a thermoplastic or of a thermoplastic elastomer.

A second (further) conductor 12 is arranged concentrically on the first cladding layer 10 and, like the first conductor 8, preferably consists of a braid, which may have an outer diameter of 4.25 mm. The second conductor 12 preferably consists of 6 × 7 individual strands of galvanized copper with a single cross section of 0.15 mm, whereby a total cross-sectional area of 42 × 0.15 mm ² = 0.75 mm ^{2 is} formed. The slope is preferably 10 mm and corresponds to a surface angle of 40 °. The optimal coverage is 65%.

Both the first conductor and the second conductor may instead of a braid in the form of a swirl screen, without crossovers, be formed, which also provides in the case of an elongation of the rope the possibility that the conductor can be stretched in the longitudinal direction, while its diameter accordingly reduced.

A second (further) jacket 14 is arranged concentrically around the second conductor 12 and preferably extruded as a tube made of plastic. The outer diameter of the second shell 14 may be about 5.0 mm +/- 0.1 mm. Like the first jacket 10, the second jacket 14 preferably consists of a high-temperature plastic, for example a thermoplastic or a thermoplastic elastomer.

In the embodiment according to Fig. 2 In contrast to the structure described above, it is provided that a (first) protective film 16 is arranged concentrically around the first conductor 8 and thus between this and the first jacket layer 10. The first protective film 16 is made of a durable plastic, in particular of PTFE with a thickness of about 0.05 mm, and may be extruded or, if made of a non-extrudable material, wound or banded.

Furthermore, it is provided that a second (further) protective film 18 is arranged around the second conductor 12, which is thus located between the latter and the second jacket layer 14. Also, this protective film consists of a mechanically and high temperature resistant plastic, preferably made of PTFE, wherein it may have a thickness of about 0.05 mm.
The second cladding layer 14 may have a slightly larger outer diameter of, for example, 5.1 mm +/- 0.1 mm in such an embodiment.

The protective films serve as a security in the event that the insulation capacity of the first cladding layer 10 and / or the second cladding layer 14 is impaired by the subsequent thermal / mechanical stretching operation of the rope.

Coaxially around the cable 1 is braided a chemical fiber rope 20 (not to scale in the drawing in diameter), for example in the form of a 12-braid with twelve strands (or about 16, 20, 24, 32 strands), each of which, for example, three Strands turned could be. The structure and thickness of the rope depend on the expected mechanical requirements (tensile load, torsional and bending stress).

After completion of the braided plastic rope 20 with the cable 1 received therein both components, the rope together with the cable received therein, thermally stretched together. The rope is subjected at a temperature of about 90 ° C to 120 ° C a stretching force of about 30% of the tensile strength of the rope. In this process, the macromolecules of the man-made fiber material constituting the tow, for example highly modular polyethylene (eg of the brand "Dyneema"), or aramid HMPA or HMPES, are oriented more extensively in the longitudinal direction than before the breaking strength of the rope is increased again and also the elongation under tensile stress is reduced.

The rope can be stretched by 1% to 30% of its original length during this stretching process, for example by 10% of its original length.

As the tubular braided rope contracts radially during the stretching operation, a strong compressive compressive force is exerted on the cable, the effects of which on the conductor (s) being largely absorbed and compensated by the leveling layer 6. Namely, the more or less uncontrolled and uneven occurring forces are compensated by the compressibility of the compensation layer. Crossover points of the conductor braid, which have an increased thickness in the radial direction, are pressed locally into the compensation layer and thus remain unhurt. Local pressure peaks resulting from the braid structure of the conductors and strands of the rope are distributed and compensated.

Moreover, as well as the rope itself, the cable is subject to longitudinal stretching, which may be particularly critical to the metallic components of the conductors. Due to the described design of the conductor with expansion reserve (mesh, spiraling, swirl screen or similar), this strain can also be compensated.

As an example, consider a reduction in diameter of the cable at a 10% elongation, based on the original unstretched length. The diameter of the core, including the leveling layer (layers 2, 4 and 6) is the same as that described above Embodiments about 2.2 mm, resulting in assuming a constant volume (approximately, neglecting local compression of the compensation layer) at 10% elongation results in a reduced diameter of about 2.10 mm, which corresponds to a reduction of 0.10 mm. All off-core components are also subject to a diameter reduction of about 0.1 mm. As an example, the compensation layer consists of about 35% compressible volume (bubbles) and about 65% of a solid component.

When the conductors 8, 12 are braided, as described, with a braid angle of 45 °, the coverage changes about 80.8% due to the reduction in diameter of the core while increasing the pitch of the braid to about 81%, which is negligible. Even with the second conductor 12, the braid coverage changes only by 1%.

Fig. 3 to 7 explain a convenient solution to the problem, a centrally running in the cable conductor or the cable through the cable networks without risk of damage to the outside. At a Kabelausführungsstelle 22 of the rope, a rigid Aufspreizkörper 24 is arranged with a rounded outer contour within the rope. The expansion body has a central passage opening 26, which extends at least from one end of the Aufspreizkörpers in this. In the in Fig. 6 illustrated example, the spreading body is hollow overall. From the passage opening 26, an outwardly opening execution opening 28 is in a substantially radial direction, the cable 1 first through the passage opening 26 into the Aufspreizkörper 24 and from there through the execution opening 28 from the Aufspreizkörper out and through the spread rope through led to the outside. The expansion body ensures that the cable locally has a much larger diameter than usual, so that the individual interwoven strands and their crossover points get an increased mutual distance, which allows the passage of the cable.

Even with a tensile load of the rope, this does not change, ie the cable is not the risk of damage by squeezing o.ä. exposed by adjacent rope strands. Fig. 3 to 5 shows another embodiment of a Aufspreizkörpers 24, which is formed substantially spindle-shaped with a passage opening 26 and an execution opening 28.

If appropriate, the cable can be protected in the region of the execution opening and the adjacent rope strands by a protective sleeve, which may be partially received in the execution opening.

Positionally, the spreading can be secured, for example, by Abbindungen 30 ("Taklings").

LIST OF REFERENCE NUMBERS

1

electric wire

2

support element

4

hard core layer

6

leveling layer

8th

first leader

10

first cladding layer

12

second conductor

14

second cladding layer

16

first protective film

18

second protective film

20

braided synthetic fiber rope

22

Cable design Point

24

Aufspreizkörper

26

Duct opening

28

exit opening

Claims (15)

1. Braided chemical fibre traction rope which is arranged around at least one electrical conductor (8, 12), characterised in that the chemical fibre traction rope together with the conductor (8, 12) contained therein is thermally stretched.
2. Braided chemical fibre traction rope according to claim 1, characterised in that contained in the chemical fibre traction rope is a cable (1) which has an insulating cylindrical core (2, 4), an insulating compensating layer (6) that encloses the core (2, 4), a braided or coiled conductor (8) that is arranged on the compensating layer (6), and an insulating casing layer (10) that encloses the conductor (8).
3. Braided chemical fibre traction rope according to claim 2, characterised in that arranged on the casing layer (10) is an additional braided or coiled conductor (12), which is enclosed by an additional insulating casing layer (14).
4. Braided chemical fibre traction rope according to claim 3, characterised in that arranged between the conductor (8) and the casing layer (10) is a protective film (16) made of plastic, which in particular comprises PTFE.
5. Braided chemical fibre traction rope according to one of the claims 3 or 4, characterised in that at least one casing layer comprises extruded plastic, in particular a thermoplastic or a thermoplastic elastomer.
6. Braided chemical fibre traction rope according to one of the claims 3 to 5, characterised in that the core has a carrier element (2) in the form of a monofilament and a core layer (4) that is extruded onto it.
7. Braided chemical fibre traction rope according to one of the preceding claims, characterised in that at a cable exit point (22), a splaying element (24) with a rounded-off outer contour is arranged within the chemical fibre traction rope, this [splaying element] having a central passage opening (26) leading out from which is an exit opening (28) that leads to the outside, wherein the at least one electrical conductor (1) is led through the passage opening (26) into the splaying element, and through the exit opening (28) out of the same, and through the splayed chemical fibre traction rope to the outside.
8. Method for manufacturing a braided chemical fibre traction rope with a conductor contained within it, with the steps:

   a) providing the electrical conductor (1; 8, 12),

   b) braiding the chemical fibre traction rope (20) around the conductor,

   c) thermally stretching the chemical fibre traction rope that contains the conductor.
9. Method according to claim 8, characterised in that step a) comprises the following steps:

   a1) providing an insulating core (2, 4),

   a2) extruding a compensating layer (6) which encloses the core (2, 4), around the core (2, 4), and

   which in particular can be elastically compressed,

   a3) arranging a braided or coiled electrical conductor (8, 12) on the compensating layer (6), a4) extruding an insulating casing layer (10) around the conductor, enclosing the conductor, in particular comprising a thermoplastic or a thermoplastic elastomer.
10. Method according to claim 8 or 9, characterised in that the chemical fibre traction rope is stretched at a temperature between 60° C and 200° C, in particular 90° C to 130° C.
11. Method according to one of the claims 9 or 10, if dependent on claim 9, characterised in that at step a), the following steps are carried out:

    - arranging an additional braided or coiled conductor (12) on the casing layer (10), and

    - extruding an additional insulating casing layer (14) around the additional conductor (12), enclosing the additional conductor (12), in particular comprising a thermoplastic or a thermoplastic elastomer.
12. Method according to one of the claims 9, 10, if dependent on claim 9 or 11, characterised in that arranged between the conductor (8) and the casing layer (10) is a protective film (16) made of plastic, in particular PTFE.
13. Method according to claim 11 or 12, characterised in that arranged between the additional conductor (12) and the additional casing layer (14) is an additional protective film (18) made of plastic, in particular PTFE.
14. Method according to one of the claims 9 to 13, characterised in that the core (2, 4) is produced by extruding a core layer (4) onto a cylindrical carrier element (2).
15. Method according to one of the claims 8 to 14, characterised in that the chemical fibre traction rope is stretched with a stretching force that is between 1% and 50%, and in particular 20% to 30%, of the tensile strength of the chemical fibre traction rope.

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