KR100571147B1 - Manufacturing method of internal thermal coating unit coated with aluminum spray - Google Patents

Abstract

The present invention is to improve the productivity of the product by coating the aluminum thermal spraying method by the arc heat, and to reduce the cost of the product, in the manufacturing method of the optical unit in which the aluminum coating layer is formed on the surface of the stainless steel tube, aluminum Melting the base material by heat to make a fine aluminum powder, it is characterized in that it comprises a coating step of blowing and coating the surface of the stainless steel tube by blowing it with high-pressure air.

Description

Manufacturing method for Aluminum spray coated anti-corrosive optical unit             

1 is a cross-sectional view of an optical composite processing ground line having an optical unit taped with aluminum according to the related art;

Figure 2 is a cross-sectional view of the optical composite processing ground line having an optical unit coated by conventional aluminum extrusion,

3 is a cross-sectional view of the optical composite processing ground line according to the present invention;

4 is a process chart for manufacturing the optical unit according to the present invention.

<Description of Symbols for Main Parts of Drawings>

1: tension member 2: optical unit

3: aluminum coating layer 4: stainless loose tube

6: fiber optic 11: preheating step

12: coating step 13: heating step

14: rolling step 15: quenching step

The present invention relates to a manufacturing method of an optical unit provided with an aluminum coating layer, in particular, by coating the aluminum by thermal spraying method to improve the productivity of the product, reduce the cost of the product, by reducing the pores of the aluminum spray layer The present invention relates to a method for manufacturing an aluminum thermal spray coated corrosion resistant optical unit to improve corrosion resistance and reduce thickness variation, thereby reducing light loss due to micro banding.

The optical composite processing ground wire having the stainless steel loose tube is a cable installed at the top of the steel tower. As shown in FIGS. 1 and 2, at least one optical unit 2 in which the optical fiber 6 is built, and the magnetic weight and external force of the cable It comprises one or more tension members (1) for supporting the load by the conductor and the conductor. At this time, the optical unit 2 is drawn out of the stainless tape and the optical fiber 6 at the same time to apply the jelly (5) to roll the stainless tape in a circular shape through a guide roller to produce a tube by laser welding. As described above, the manufactured optical unit 2 alternately speaks in a spiral direction together with the tension member 1 and the conductor to form an optical composite processing branch line in the form of a cable.

At this time, since the optical fiber 6 tends to generate micro bending loss due to side pressure or the like, the optical unit 2 is formed to have a diameter smaller than that of the tension member 1 and the conductor. By allowing a predetermined gap to be generated, the external stress is prevented from being transmitted to the optical unit 2, thereby reducing the optical loss.

In addition, the tension member 1 is coated on the surface of aluminum while the optical unit 2 is wrapped in a stainless tube, so that galvanic corrosion may occur due to a potential difference between aluminum and stainless steel. In order to prevent this, the surface of the optical unit 2 is coated with aluminum to prevent corrosion. The coating method of the optical unit 2 may include a tape ending, an electroplating method, or a deposition method. In some cases, grease may be filled between wires to prevent corrosion.

In this case, the aluminum tape ending method is torn or gap of the end portion (7) during the twisted pair or during the temporary construction, or when the tape is dropped or opened due to the degradation of the adhesive strength due to deterioration of the adhesive during long-term construction Moisture or contaminants penetrate and cause galvanic corrosion, such as the corrosion prevention effect is significantly reduced.

In addition, since the coating method by aluminum extrusion extrudes aluminum heated to about 500 ° C. at high temperature and high pressure, the jelly 5, the optical fiber 6, and the binder yarn in the stainless loose tube 4 due to high temperature deteriorate. There are various problems such as problems such as deformation and tearing of the stainless steel tube 4 due to high pressure during extrusion.

In this extrusion method, since the size and weight of the optical unit 2 increases as the aluminum layer is difficult to form to a thickness of 0.35 mm or less, the size and weight of the overall cable also increase in proportion to each other. There are various problems such as an increase in processing costs and a cause of ground faults and short circuits during construction.

In addition, the aluminum electroplating method cannot be plated in an aqueous solution, so a special solvent is required, and thus the processing cost increases, and there is a risk of explosion during plating. There is a problem of this deterioration.

Grease (charase) filling method has a problem that the grease is hardened by deterioration for a long time, or the grease is leaked to the outside during heavy rain to reduce the corrosion protection effect, the operation time is delayed by the grease during the optical connection work.

The present invention has been made in view of the above problems, and the first object of the present invention is to coat aluminum on the surface of a stainless steel tube by thermal spraying to improve the productivity of the product and reduce the cost of the product. It is to provide a method of manufacturing a thermally coated aluminum thermal coating optical unit.

In addition, the second object of the present invention is a thermal spray coating of aluminum, and then preheating and rolling the aluminum coating layer, to reduce the thickness deviation and porosity of the aluminum coating layer, the aluminum thermal spray coating coated optical unit manufacturing method that can prevent corrosion. To provide.

In order to achieve the above object, the present invention, in the manufacturing method of the optical unit in which the aluminum coating layer is formed on the surface of the stainless steel tube, by melting the aluminum base material by heat to make fine aluminum powder, by blowing it with high-pressure air It is a manufacturing method of an optical unit comprising a coating step of spraying and coating on the surface of the stainless steel tube.

Preferably, the aluminum coating layer in the coating step is coated with a thickness of 5 ~ 100㎛.

And, the aluminum coating layer in the coating step is more preferably coated with a thickness of 80 ~ 90㎛.

And, it is characterized in that it further comprises a preheating step of preheating the stainless steel tube to 50 ~ 100 ℃ before the coating step.

And, the blasting step of forming irregularities on the surface of the stainless loose tube before the preheating step.

And, the coating step is characterized in that the coating by re-spraying the aluminum powder two or more times while recycling the stainless steel tube in a predetermined path.

After the coating step, a heating step of heating the aluminum coating layer to 100 to 700 ° C., a rolling step of reducing porosity and thickness deviation of the aluminum coating layer by rolling the aluminum coating layer heated by the heating step, and the rolling step A quenching step of quenching the optical unit to prevent deterioration inside the optical unit is further included.

In addition, in the rolling step, the thickness of the aluminum coating layer is 15 to 20% reduced by pressure rolling.

On the other hand, there is an optical composite processing branch including one or more optical units manufactured by the manufacturing method as described above.

Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.

3 is a cross-sectional view of the optical composite processing ground line according to the present invention, Figure 4 is a process chart for manufacturing the optical unit according to the present invention.

Referring to FIGS. 3 and 4, an optical unit 2 including one or more optical fibers, one or more tension members 1 for supporting a load caused by the weight and external force of a cable, and a light composite including a conductor In the processing branch line, it is to be able to form the aluminum coating layer (3) in the optical unit in order to prevent the galvanic corrosion generated between the constituent material stainless and aluminum.

At this time, the optical unit 2 is drawn out of the stainless tape and at least one optical fiber (6) at the same time to apply the jelly (5) to roll the stainless tape in a circular shape through a guide roller and welded with a laser or the like to produce a tube form. .

The thermal spray coating step 12 is a step of forming an aluminum base material on the periphery of the stainless steel tube (4) to form a fine powder by arc heat and then blowing it by high-pressure air to spray coating a pair of 1.2-2.0 mm diameter. By supplying power to the aluminum base material in the form of wire is blown with high-pressure air while melting the aluminum in the arc heat of 3000 ~ 4000 ℃ so that the fine powder of aluminum is coated on the surface of the stainless steel loose tube (4). At this time, the air which sprays aluminum powder is sprayed by the pressure of 3-10 kgf / cm <2>.

Determination of the maximum thickness of the aluminum coating layer (3) formed in the thermal spray coating step (12) is dependent on the conditions of use, warranty period, and the corrosion environment, the minimum thickness is enough to be peeled off by friction and external load between the wires during manufacture. Although it determines with the thickness of, it is preferable to form in thickness of 5-100 micrometers, and it is more preferable to form in 80-90 micrometers. At this time, the aluminum coating layer may be peeled off due to friction in the case of 5 μm or less, which may cause galvanic corrosion. In the case of 100 μm or more, the size and weight of the cable increase, so that the overall size and weight of the cable increases proportionally. There is a disadvantage that the processing cost and the like increases.

Before the coating step 12, it is preferable to go through a preheating step (11) for preheating the stainless steel tube (4) to 50 ~ 100 ℃, when the thermal spray material attached to the surface of the stainless steel tube (4) in the coating step Since the temperature is at about 50 to 100 ° C, the preheating of the stainless loose tube 4 reduces the temperature difference with the aluminum powder to be adhered to prevent the aluminum powder from falling off due to heat shrinkage. In addition, at such a preheating temperature of 50 to 100 ° C, deterioration of the jelly 5, the optical fiber 6, and the binder yarn in the optical unit 2 is prevented.

As a pretreatment step of the preheating step 11 and the coating step 12, the surface of the optical unit 2 is washed 9 to remove fresh oil from the surface during the manufacturing of the optical unit 2, and the stainless loose tube ( The surface of 4) is preferably blasted 10 with an air pressure of 5 to 7 kgf / cm 2 to form irregularities on the surface so that the aluminum powder easily adheres.

The coating step 12 is again sprayed two or more times by passing back through the stainless steel tube (4) passed through the thermal spraying capstan (8) in order to reduce the loss of aluminum, the thermal spraying material and obtain the target thickness within a short time It is desirable to. The number of resprays depends on the speed and the target thickness. For example, if the flux is 20mpm and the target thickness is 80㎛, respraying three times can reduce the loss of aluminum by more than 65%.

After preheating the stainless steel tube 4 and spray-coated aluminum on the surface thereof, the heating step 13, the rolling step 14, and the quenching step 15 are performed to reduce the thickness deviation and porosity of the aluminum coating layer 3. It is desirable to pass through. There may be about 15% of pores in the aluminum coating layer 3, and since corrosion may occur through the pores, to prevent this, the aluminum coating layer 3 is heated and rolled to closely dense internal tissues. This removes pores and prevents corrosion.

The heating step 13 makes it easy to deform by heating the stainless steel tube (4) formed with the aluminum coating layer 3 to 100 ~ 700 ℃ instantaneously. The aluminum coating layer (3) is heated to 100 ~ 700 ℃ to be rolled in a softened state of the tissue must be rolled smoothly between the aluminum particles can be effectively reduced pore and thickness deviation. At this time, as the heating temperature increases, it becomes easier to roll the aluminum coating layer, but when the temperature becomes 700 ° C or higher, the aluminum melting temperature becomes higher or higher, resulting in poor workability, or the jelly 5, the optical fiber 6, and the binder yarn inside the optical unit 2. There is a risk of deterioration. In addition, the heating step may be heated for a short time at a high temperature to prevent deterioration of the jelly 5, the binder and the optical fiber 6 in the optical unit (2).

Rolling step 14 is a pore and thickness present in the aluminum coating layer 3 by rolling the aluminum coating layer 3 heated to 100 ~ 700 ℃ by the heating step 13 so that the thickness is reduced by 15 to 20% It is to reduce the deviation. When a thickness variation of 10 to 15 μm occurs in the aluminum coating layer 3, it is difficult to secure a 0.05 mm gap between the optical unit 2, the tension member 1, and the conductor in a later process. Since light loss may occur, it is necessary to make the thickness of the aluminum coating layer 3 uniform. The aluminum coating layer 3 formed to a thickness of 5 ~ 100㎛ in the coating step 12 is uniformly molded while reducing to a thickness of 4 ~ 85㎛ through the rolling step (14).

In the quenching step 15, as the aluminum coating layer 3 is heated to 100 to 700 ° C. and rolled, the quenching step 15 is quenched before hot air is transferred to the optical unit 2 immediately after the rolling step 14. It is to prevent deterioration of the jelly 5 and the binder and the optical fiber 6 therein.

As described above, the manufactured optical unit 2 forms an optical cable by alternately speaking in the SZ direction together with the tension member 1 and the conductor, and external stress is transmitted to the optical unit 2 at the time of twisting and installing the temporary structure. In order to prevent this, the diameter of the optical unit 2 is molded smaller than the tension member 1 and the conductor so that a gap of about 0.05 mm is generated around the optical unit 2 after the stranded wire.

At least one optical unit 2 manufactured by the above method is included to form the optical composite processing line.

According to the present invention as described above, since the aluminum is coated on the surface of the stainless steel loose tube by spraying, the adhesion with the stainless steel loose tube is excellent and the structure is dense, the corrosion resistance is improved, of course, 80 ~ 90 As the coating is made in the form of a thin thin film, the size and weight of the product are reduced and the optical connection work is easy.

In addition, by re-spraying aluminum on the surface a plurality of times while recycling the stainless loose tube in a predetermined path, the productivity of the product is improved, there is an advantage that can reduce the coating material.

And, by rolling to reduce the thickness of the aluminum coating layer by 15 to 20%, there is an advantage that the corrosion resistance is further improved by removing the pores present in the aluminum coating layer. In addition, the aluminum coating layer heated during the rolling operation may be quenched to prevent deterioration of the jelly, the binder, and the optical fiber in the optical unit.

In addition, the aluminum coating layer has a uniform thickness as it passes through the heating and rolling steps, so that a constant gap is generated around the optical unit at the time of stranding, thereby reducing light loss such as micro banding due to external load. Through this heating and rolling step is adhered to be in close contact with the surface of the stainless steel loose tube has the advantage of reducing the surface peeling phenomenon.

Claims (9)

In the manufacturing method of the optical unit in which the aluminum coating layer is formed on the surface of the stainless steel tube, Method of manufacturing an aluminum thermal spray coated corrosion resistant optical unit comprising a coating step of melting the aluminum base material by heat to make a fine aluminum powder, blowing it with high-pressure air to the surface of the stainless loose tube by coating. . The method of claim 1, The aluminum coating layer in the coating step is aluminum spray coating coated optical unit manufacturing method, characterized in that coated with a thickness of 5 ~ 100㎛. The method of claim 2, The aluminum coating layer in the coating step, the aluminum thermal spray coating of the internal coating optical unit, characterized in that the coating to a thickness of 80 ~ 90㎛. The method of claim 1, The pre-coating step of preheating the stainless steel tube to 50 ~ 100 ℃ preheating step of aluminum spray coating coated optical unit manufacturing method characterized in that it further comprises. The method of claim 1, And a blasting step of forming irregularities on the surface of the stainless loose tube before the preheating step. The method of claim 1, The coating step is a method of manufacturing a thermal spray coating of the aluminum-coated coated optical unit, characterized in that the coating by re-spraying the aluminum powder two or more times while recycling the stainless steel tube in a predetermined path. The method of claim 1, A heating step of heating the aluminum coating layer to 100 to 700 ° C. after the coating step; and Rolling step of reducing the pore and thickness deviation of the aluminum coating layer by rolling the aluminum coating layer heated by the heating step; And The quenching of the optical unit passed through the rolling step to prevent the deterioration of the inside of the optical unit is a thermal spraying coated aluminum optical unit manufacturing method, characterized in that the configuration further comprises. The method of claim 7, wherein The rolling step is a method of manufacturing an aluminum thermal spray coated corrosion resistant optical unit, characterized in that the pressure rolling to reduce the thickness of the aluminum coating layer 15 ~ 20%. delete

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