KR20190057478A - A Method for Producing a Copper Clad Aluminum for Communication and the Copper Clad Aluminum Produced by the Same - Google Patents

Abstract

The present invention relates to a method for manufacturing a copper clad aluminum (CCA) cable for communications and a CCA cable manufactured thereby and, more specifically, to a method for manufacturing a CCA cable for communications, which is formed by coupling a plurality of CCA strands, and a CCA cable manufactured thereby. According to the present invention, the method for manufacturing a CCA cable for communications comprises the steps of: continuously coating an aluminum rod while forming a copper tape into a pipe shape to form a CCA wire; forming the CCA wire by a preliminary diameter by a first drawing process while passing the CCA wire through a dice mold; forming a preliminarily drawn CCA wire into a CCA strand with a predetermined diameter by a second drawing process; forming an insulated strand by coating an insulating material on a surface of the CCA strand and twisting different insulated strands to form a twisted strand; twisting different twisted strands while adjusting a pitch to form a united strand; and forming an outer sheath on the united strand.

Description

[0001] The present invention relates to a method for manufacturing a copper-clad aluminum cable for communication, and a method for producing the aluminum clad copper cable,

The present invention relates to a method of manufacturing a coplanar aluminum cable for communication and a coplanar aluminum cable produced thereby, and more particularly, to a method of manufacturing a coplanar aluminum cable for communication formed by connecting a plurality of coplanar aluminum strands together, .

The copper-coated aluminum wire rod has the advantage of being lightweight and cost-saving while having the same electrical characteristics as the copper wire rod by coating the periphery of the aluminum core with copper. However, since the copper alloy wire rod is a composite material, it is difficult to manufacture and has to have electrical characteristics suitable for each application. Another problem with copper clad aluminum (CCA) materials is that there is no standard for electrical certification, and it is difficult to mass produce them with the specified product specifications. However, due to the various advantages of copper wire aluminum wire, related technologies are being developed in various forms.

Patent Registration No. 10-1417999 discloses a method for manufacturing a copper alloy aluminum wire rod to improve a heterogeneous bonding interface property between copper and aluminum to provide a stable and uniform product. In addition, Patent Publication No. 10-2013-0102773 discloses a copper alloy wire rod capable of exhibiting an electrical characteristic equivalent to that of a wire made of a conventional copper wire without significantly increasing the outside diameter, and a compression conductor including the same, And a manufacturing method thereof.

Prior art or publicly known technology does not disclose a method in which coaxial aluminum wire is made to conform to a copper communication cable or a coaxial aluminum cable made in such a way.

The present invention has been made to solve the problems of the prior art and has the following purpose.

Prior Art 1: Patent Registration No. 10-1417999 (Korea Electrotechnology Research Institute, Aug. 06, 2014) Manufacturing method of copper wire aluminum wire Prior Art 2: Patent Publication No. 10-2013-0102773 (published by LS Cable, Inc. on Sep. 23, 2013) Composite aluminum wire, compressed conductor including the same, cable and method of manufacturing compressed conductor

It is an object of the present invention to provide a method of manufacturing a coaxial aluminum cable for communication which can be applied for communication, and a coaxial aluminum cable manufactured thereby.

According to a preferred embodiment of the present invention, a method for manufacturing a coplanar aluminum cable for communication and a coplanar aluminum cable produced therefrom is a method for manufacturing a copper clad aluminum (CCA) by continuously coating an aluminum rod while forming a copper tape into a pipe shape, Forming a wire rod; Molding the CCA wire into a preliminary diameter by a wire drawing process while passing through the die mold; Molding the primary drawing CCA into a CCA strand having a predetermined diameter by a secondary drawing process; Forming an insulating strand with the surface of the CCA strand as an insulating material, and twisting the different insulating strands to form a twisted strand; Twisting differently twisted strands to form stranded strands while adjusting the pitch; And forming an outer sheath on the coalescing strand.

According to another preferred embodiment of the present invention, the insulating strand comprises a polyethylene (PE) coating layer and the outer covering is polyvinyl chloride.

According to another preferred embodiment of the present invention, there is provided a composite strand comprising a plurality of mutually twisted pairs of strands formed by coplanar aluminum; And an outer sheath of cohesive strands, with reference temperature coefficients of 20 ° C and 25 ° C being 1.038 to 1.050 and 1.058 to 1.068, respectively.

According to another preferred embodiment of the present invention, after burning for 20 minutes in the flame retardancy test, the sample should not be burned to the upper end and there should be no damage such as occurrence of ash and charcoal.

According to another preferred embodiment of the present invention, the attenuation level is between 2.0 and 22 dB / 100 M at 1 MHz to 500 MHz.

The manufacturing method according to the present invention makes it possible to provide a communication cable capable of reducing the manufacturing cost by about 30% while having a communication characteristic equivalent to that of a copper cable for communication or a similar material. The communication-use aluminum cable for communication according to the present invention can be applied to a communication cable for various purposes including a LAN cable for internet communication or a cable for internet signal, which is required for high-speed signal transmission installed in a building.

1 shows an embodiment of a manufacturing process of a coplanar aluminum cable according to the present invention.
Fig. 2 shows an embodiment of a coplanar aluminum cable according to the present invention.
3A to 3G show measurement results of electrical characteristics of a CCA cable according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to the embodiments shown in the accompanying drawings, but the present invention is not limited thereto. In the following description, components having the same reference numerals in different drawings have similar functions, so that they will not be described repeatedly unless necessary for an understanding of the invention, and the known components will be briefly described or omitted. However, It should not be understood as being excluded from the embodiment of Fig.

1 shows an embodiment of a manufacturing process of a coplanar aluminum cable according to the present invention.

Referring to FIG. 1, a method for manufacturing a coplanar aluminum cable for communication includes forming a copper-clad aluminum (CCA) wire by continuously coating an aluminum rod while forming a copper tape into a pipe shape (P12); (P13) of forming the CCA wire into a preliminary diameter by a first drawing process (wire drawing) while passing the die metal mold; Molding the primary drawing CCA into a CCA strand having a predetermined diameter by a secondary drawing process (P14); Forming an insulating strand of the surface of the CCA strand with an insulating material, and forming twisted strands of different insulating strands (P15); (P16) of forming twisted strands by twisting different twisted strands while adjusting the pitch; And forming an outer coating on the coalescing strand (P17).

CCA wire needs to be made for the manufacture of copper copper alloy (CCA) cables for communications. The CCA wire needs to be made to conform to the communication quality, for example, to have a uniform diameter along the length direction. Copper for coating aluminum surfaces can be prepared in tape form (P11); The copper tape may be, for example, in the form of a linear plate. The aluminum forming the core may be a rod shape having a circular cross section, for example, while being a linear rod shape.

As the aluminum rod is fed by the conveyed copper tape, the copper tape can be made into a pipe shape while wrapping the aluminum rod, whereby the CCA wire can be made (P12). The CCA wire is formed by coating the circumference of the aluminum rod with a uniform thickness of copper, the copper can be an oxygen-free high purity copper, and the thickness of the copper covering the aluminum rod Can be determined based on the skin depth of the electrical signal. When the CCA wire is formed (P12), the wire drawing for the CCA wire may proceed (P13).

The drawing process may proceed by applying the tension while continuously passing the CCA wire through the die mold (P13), and the CCA wire may be made uniform in its entirety by the primary drawing process. By the primary drawing process, the CCA wire can be made to have a mean preliminary diameter of, for example, 2.0 to 3.5 mm in thickness, preferably 2.4 to 3.0 mm. The secondary drawing process can be performed so that the CCA wire having a uniform diameter has a predetermined diameter to be used as a wire for a communication cable (P14).

The secondary drawing process for the CCA wire may be made to have a diameter of 0.15 to 0.35 with respect to the diameter of the CCA wire by the primary drawing process. For example, the diameter of the CCA wire may be 0.30 to 1.23 mm Lt; RTI ID = 0.0 > 0. < / RTI > When the CCA wire is formed into a CCA strand by a secondary drawing process (P14), it may become an insulating coating (P15).

The insulating sheath may be made of, for example, polyethylene or similar material, but may include a flame retardant material if desired. The flame retardant material can be, but is not limited to, for example, polyurethane foam, silicon based fluorine compounds, pyridine compounds, inorganic compounds, or similar flame retardant compounds. Since the communication characteristics may be deteriorated by the addition of the flame retardant compound, the flame retardant compound needs to be used in a limited amount, for example, a flame retardant compound of 0.1 to 5 wt% based on the weight of the polyethylene may be added. Alternatively, the thickness of the coating of the insulating coating material such as polyethylene can be suitably adjusted. As such, the CCA strand can be an insulating sheath with a synthetic resin insulating material that does not include or contain a flame retardant compound, and the insulating sheath can be made of a plurality of insulating sheath strands of different colors.

Once the insulating sheaths of different colors are ready (P15), a pair of insulating strands of different colors can be twisted to form twisted strands (P16). Twisted strands isolated eg white isolated strand and red jack isolated strand; Isolated on white strands and blue color isolated strands; Isolated on white Strands and green insulated strands; Alternatively, a plurality of pairs of twisted strands may be made, which may be made in the form of a strand of white insulated strands and a strand of yellow insulated strands, and of twisted insulating strands of different colors. For example, four pairs of twisted strands are made, and four pairs of twisted strands can have different colored covers. When a plurality of pairs of twisted strands having different colors are thus formed (P16), a combined process of associating a plurality of pairs of twisted strands together can proceed (P17).

The associative process can be accomplished in a manner, for example, by combining four pairs of twisted strands of different colors, and a wire for a communication cable can be made by a combined process. Thus, the outer coating process may proceed if a coalesced spiral is formed by the coalescence process in which a plurality of twisted strands are associated with each other (P17). The outer coating process may be performed by, for example, a method of coating with polyvinyl chloride, and the synthetic resin material for coating may include a flame retardant compound. For example, from 0.1 to 5 wt% polyurethane foam, silicone based fluorine compound, pyridine compound, inorganic compound or similar flame retardant compound.

The CCA strand may be elongated due to the characteristics of aluminum in the insulating process or the combined process, and the moving speed of the CCA strand or twisted strand needs to be appropriately adjusted in order to prevent it. For example, the CCA strands or twisted strands need to be moved at a speed of 500 to 700 m / min, preferably at a speed of 550 to 650 m / min. Such a moving speed corresponds to a moving speed of 75 to 85% of the moving speed when the same process is performed for a conductor such as copper, for example. The CCA cable made through this process can be applied to various communication cables.

The following describes the CCA wire made in each process.

Fig. 2 shows an embodiment of a coplanar aluminum cable according to the present invention.

Referring to FIG. 2, the associated strands 22 may be formed by a plurality of twisted strands 21a, 21b, 21c, 21d of different pairs of CCA strands. Each twisted strand 21a, 21b, 21c, 21d may be twisted to have a pitch of, for example, 8 to 15 mm, preferably 9 to 13 mm. The joined strand 22 formed by the four pairs of twisted strands 21a, 21b, 21c and 21d may also have a pitch of 100 to 150 mm, preferably 110 to 130 mm. Also, the CCA communication cable 23 with an outer sheath may have an average diameter of 5.0 to 6.0 mm, preferably an average diameter of 5.10 to 5.20 mm.

The CCA cable for communication can be made into various standards depending on the use, and is not limited to the illustrated embodiment.

The CCA cable for communication according to the invention can consist of a plurality of mutually twisted pairs of co-stranded aluminum stranded outer strands and a co-strand outer cladding, for example 20 ° C and 25 ° C reference temperature coefficients of 1.038 to 1.050 and 1.058 to 1.068. In addition, the combustion delay time for a length corresponding to 10 times the diameter of a copper cable can be 20 minutes or more. In addition, the attenuation level can be 2.0-22 dB / 100M at 1 MHz to 500 MHz.

Measurements were made for the embodiments shown in Figures 1 and 2 and measurements were made to determine if the manufactured CCA cable is suitable for communication.

Test items for measurement are as follows.

- Conductor resistance

Since KS C 3342: 2016, which is a measurement standard for conductor resistance, is applied to copper conductors, the temperature coefficient and the maximum resistance value are measured by applying UL 2556 and 1584 to determine whether the CCA cable is suitable for communication.

The maximum resistance value was shown to be appropriate for the communication cable, and the measurement results of the temperature coefficient were as shown in Table 1 below.

Table 1: Temperature coefficient measurement results Temperature (℃) 20 ℃ reference temperature coefficient Based on 25 ℃  Thermometer number 10 1.042 1.063 11 1.038 1.059 12 1.033 1.054 13 1.029 1.050 14 1.024 1.045 15 1.020 1.041 16 1.016 1.037 17 1.012 1.033 18 1.008 1.028 19 1.004 1.024 20 1,000 1.020 21 0.996 1.016 22 0.992 1.012 23 0.988 1.008 24 0.984 1.004 25 0.980 1,000 26 0.976 0.996 27 0.972 0.992 28 0.969 0.989 29 0.965 0.985 30 0.961 0.981 31 0.957 0.977 32 0.954 0.973 33 0.950 0.970 34 0.947 0.966 35 0.943 0.962

CCA communication cable was classified as below and the measurement was carried out to judge whether or not the manufactured CCA communication cable is suitable for communication.

Table 2: CCA Symbols, Ratings, and Insulator Types sign Rating Types of Insulators division Maximum frequency CM 5E rating Up to 100MHz HDPE (density 0.941g / cm ³ Polyethylene)

The results measured according to the classification standard are shown in FIGS. 3A to 3G.

- Flammability test

The flame retardancy test was carried out in accordance with UL 1685 8.3.3, with a width of 300 mm and a depth of 76 mm. The CCA cables fabricated according to the embodiment shown in Figs. 1 and 2 were vertically arranged at a ladder of 2,400 mm in height at an interval of 10 times the diameter. After 20 minutes of burning, the possibility of fire occurrence and prevention of diffusion was examined.

As a result of the test, it was found that the combustion function was maintained at least 80% after the combustion was delayed for more than 20 minutes.

As can be seen from the above measurement results, it can be seen that the CCA cable manufactured according to Figs. 1 and 2 is suitable for communication.

The manufacturing method according to the present invention makes it possible to provide a communication cable capable of reducing the manufacturing cost by about 30% while having a communication characteristic equivalent to that of a copper cable for communication or a similar material. The communication-use aluminum cable for communication according to the present invention can be applied to a communication cable for various purposes including a LAN cable for internet communication or a cable for internet signal, which is required for high-speed signal transmission installed in a building.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention . The invention is not limited by these variations and modifications, but is limited only by the claims appended hereto.

21a, 21b, 21c, 21d: twisted strands 22:
23: CCA communication cable

Claims (5)

Forming a copper-clad aluminum (CCA) wire by continuously coating an aluminum rod while forming a copper tape into a pipe shape;
Molding the CCA wire into a preliminary diameter by a wire drawing process while passing through the die mold;
Molding the primary drawing CCA into a CCA strand having a predetermined diameter by a secondary drawing process;
Forming an insulating strand with the surface of the CCA strand as an insulating material, and twisting the different insulating strands to form a twisted strand;
Twisting differently twisted strands to form stranded strands while adjusting the pitch; And
And forming an outer sheath on the co-strand. The method of claim 1, wherein the insulating strand comprises a polyethylene (PE) coating layer and the outer sheath is polyvinyl chloride. A coherent strand composed of a plurality of mutually twisted pairs formed by copper alloy; And
Wherein the reference temperature coefficient at 20 占 폚 and 25 占 폚 is 1.038 to 1.050 and 1.058 to 1.068, respectively. The flame-resistant aluminum cable according to claim 3, characterized in that it is not burned to the upper end of the sample after combustion for 20 minutes in the flame retardancy test, and there is no damage such as occurrence of ash and charcoal. The coaxial aluminum cable according to claim 3, wherein the attenuation level is from 2.0 to 22 dB / 100 M at 1 MHz to 500 MHz.

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