WO2020228288A1 - 一种高可靠柔性抗扭低压电缆及其制作方法 - Google Patents

一种高可靠柔性抗扭低压电缆及其制作方法 Download PDF

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Publication number
WO2020228288A1
WO2020228288A1 PCT/CN2019/118566 CN2019118566W WO2020228288A1 WO 2020228288 A1 WO2020228288 A1 WO 2020228288A1 CN 2019118566 W CN2019118566 W CN 2019118566W WO 2020228288 A1 WO2020228288 A1 WO 2020228288A1
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Prior art keywords
semi
conductive
conductor
wall
tape
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PCT/CN2019/118566
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English (en)
French (fr)
Inventor
陆春良
田敏
王国权
吴士杰
冯成
宋志斌
席娇娜
Original Assignee
江苏亨通线缆科技有限公司
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Priority to ES202090004U priority Critical patent/ES1290695Y/es
Publication of WO2020228288A1 publication Critical patent/WO2020228288A1/zh

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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
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • 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
    • H01B13/2606—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by braiding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
    • H01B7/041—Flexible cables, conductors, or cords, e.g. trailing cables attached to mobile objects, e.g. portable tools, elevators, mining equipment, hoisting cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/22—Metal wires or tapes, e.g. made of steel
    • H01B7/228—Metal braid

Definitions

  • This application relates to the field of cable technology, and specifically to a high-reliability, flexible torsion resistant low-voltage cable and a manufacturing method thereof.
  • the cables For mobile cables used in the industrial field, such as welding machine cables, the cables need to be dragged, bent and twisted during use. Due to the aging of the cable's own material and the action of external mechanical stress, the cable will last for a long time. In the process of use, it is easy to cause the phenomenon of insulation breakage.
  • the conventional method for detecting insulation breakage is manual visual inspection. Due to the low efficiency of manual visual inspection and the high rate of missed detection, in many cases the insulation breakage cannot be found in time, and when the insulation is broken, there will be Different levels of electrical leakage will cause potential safety hazards to the equipment and make the safety of the operators insecure.
  • This application provides a high-reliability, flexible, torsion-resistant low-voltage cable and a manufacturing method thereof.
  • the cable and the cable manufactured by the manufacturing method can at least achieve the technical effect of efficient leakage detection.
  • This application provides a high-reliability, flexible, torsion-resistant low-voltage cable, which includes a conductor, an insulating layer, a semi-conductive tape, and a metal braid.
  • the insulating layer is arranged on the outer wall of the conductor.
  • the semi-conductive tape is wrapped around the outer wall of the insulating layer.
  • the metal braid is arranged on the outer wall of the semi-conductive wrapping tape.
  • the application provides a reliable leakage detection cable, which can at least achieve the following technical effects: wherein the conductor is protected by the insulating layer, and the semi-conductive tape wraps around the outer wall of the insulating layer to form a monitoring layer.
  • the layers are connected by wrapping, so the monitoring layer can fully cover the outer wall surface of the insulating layer.
  • the metal braid layer is arranged on the outer wall of the semi-conductive tape. The metal braid layer improves the torsional and tensile performance of the cable on the one hand, and on the other hand, the metal braid layer can also be used for leakage detection. Among them, when the insulating layer is damaged, the conductor Leakage will occur.
  • the current will be conducted to the conductive metal wire in the metal braid through the semi-conductive tape.
  • the conductive metal wire in the metal braid can be The leakage signal is transmitted to the leakage protection device to realize the operation of reminding or power-off, thereby ensuring the safety and reliability of the cable.
  • the wrapping joint of the semi-conductive wrapping tape is fixed by a semi-conductive tape.
  • the technical effects include at least: the semi-conductive tape is fixed on the insulating layer through the semi-conductive tape, which can ensure the integrity of the semi-conductive tape and the insulating layer, and at the same time ensure that the monitoring layer formed by the semi-conductive tape is in place. Electrical conductivity throughout the cable.
  • the wrapping joint of the semi-conductive wrapping tape is bonded and fixed by semi-conductive glue.
  • the semi-conductive tape is fixed on the insulating layer by the semi-conductive glue, which ensures the integrity of the semi-conductive tape and the insulating layer, and also ensures that the monitoring layer composed of the semi-conductive tape is in the entire cable The conductive properties.
  • the surface of the conductive metal wire in the metal braid is tin-plated.
  • the technical effect at least includes: plating the surface of the conductive metal wire to improve its corrosion resistance, and at the same time, it can also improve the weldability of the conductive metal wire.
  • the cable further includes an outer sheath, and the outer sheath is disposed on the outer wall of the metal braid.
  • the technical effects at least include: by providing an outer sheath on the outer wall of the metal braid, the cable can be used in various harsh environments under the protection of the outer sheath.
  • the conductor adopts Super Category 6 super soft copper conductor
  • the outer surface of the single wire of the conductor is tin-plated.
  • the tape material of the semi-conductive tape is a non-woven fabric with semi-conductive properties.
  • the semi-conductive tape forms a monitoring layer on the outer wall of the insulating layer, and the surface resistivity of the monitoring layer is less than 1500 ohms.
  • the wrapping rate of the monitoring layer is one-quarter to one-half.
  • the metal braid layer includes mixed braided copper wires and high-performance fibers.
  • This application provides a method for manufacturing a cable, which includes:
  • the metal braid is arranged on the outer wall of the semi-conductive tape.
  • the present application provides a method for manufacturing a cable capable of realizing leakage detection, wherein at least the following technical effects can be achieved: the outer wall of the conductor is provided with an insulating layer for insulation isolation, and the semi-conductive tape is wrapped
  • the monitoring layer is formed on the outer wall of the insulating layer. Since the monitoring layer is connected by wrapping, the monitoring layer can fully cover the outer wall surface of the insulating layer.
  • the metal braid is arranged on the outer wall of the semi-conductive tape, and the metal braid is used to improve the torsion and tensile resistance of the cable on the one hand, and on the other hand, the metal braid can also be used for leakage detection.
  • the conductor when the insulating layer is damaged, The conductor will leak, and the current will be conducted to the conductive metal wire in the metal braid through the semi-conductive tape.
  • the conductive metal wire in the metal braid By connecting the conductive metal wire in the metal braid with the leakage protection device, the conductive metal wire in the metal braid The leakage signal can be transmitted to the leakage protection device to realize the operation of reminding or power off, thereby ensuring the safety and reliability of the cable.
  • the method further includes:
  • the insulating material is extruded on the conductor by an extruder to form an insulating layer.
  • the technical effect at least includes: the insulating material can be heated and plasticized by the extruder and uniformly extruded on the conductor to ensure that the outer wall of the conductor can cover the insulating layer smoothly and completely.
  • the step of extruding the insulating material on the conductor through an extruder further includes:
  • the insulating material is heated and plasticized by an extruder to be evenly extruded on the conductor.
  • the step of heating and plasticizing the insulating material further includes:
  • the extruder adopts a semi-extrusion tube mold, the temperature range of each section of the extruder is 170°C-200°C, and the temperature range of the die head is 210°C-230°C.
  • the method further includes:
  • the technical effects include at least: the semi-conductive tape is fixed on the insulating layer through the semi-conductive tape, which can ensure the integrity of the semi-conductive tape and the insulating layer, and at the same time ensure that the monitoring layer formed by the semi-conductive tape is in place. Electrical conductivity throughout the cable.
  • the method further includes:
  • Copper wires and high-performance fibers are braided by a braiding machine to form a metal braid.
  • the production method further includes:
  • thermoplastic polyurethane elastomer is extruded on the metal braid through an extruder to form an outer sheath.
  • the technical effect at least includes: by providing an outer sheath on the outer wall of the metal braid, the cable can be used in various harsh environments under the protection of the outer sheath.
  • the outer sheath is formed by extruding the thermoplastic polyurethane elastomer on the metal braid through an extruder. Since the outer sheath is formed by extruding by the extruder, the outer sheath can be evenly and completely covered on the metal The outer wall of the braided layer.
  • the outer sheath is made of thermoplastic polyurethane elastomer
  • the outer sheath has super wear resistance, scratch resistance, high strength, and excellent low temperature resistance, flame resistance, grease and acid resistance
  • the performance of alkali chemicals, so the cable can be used in various harsh environments under the protection of the outer sheath.
  • Figure 1 is a specific structure of a cable in an embodiment of the application
  • Figure 2 is a specific structure of another cable in an embodiment of the application.
  • Figure 3 is a schematic diagram of a method for manufacturing a cable in an embodiment of the application.
  • Fig. 4 is a schematic diagram of another method for manufacturing a cable in an embodiment of the application.
  • Icon 10-high-reliability, flexible, torsion-resistant low-voltage cable; 11-conductor; 12-insulation layer; 13-semi-conductive tape; 14-metal braid; 15-outer sheath; 20-production method.
  • connection may also be a detachable connection or an integral connection; it may be a direct connection or an indirect connection through an intermediate medium, and it may be a communication between two components.
  • connection may also be a detachable connection or an integral connection; it may be a direct connection or an indirect connection through an intermediate medium, and it may be a communication between two components.
  • This embodiment provides a cable that can efficiently perform leakage detection.
  • FIG. 1 shows a specific structure of a high-reliability, flexible, torsion-resistant low-voltage cable 10 provided in this embodiment.
  • the high-reliability, flexible, torsion-resistant low-voltage cable 10 includes a conductor 11, an insulating layer 12, a semi-conductive wrapping tape 13, and a metal braid layer 14.
  • the insulating layer 12 is provided on the outer wall of the conductor 11.
  • the semi-conductive tape 13 is wrapped around the outer wall of the insulating layer 12.
  • the metal braid layer 14 is arranged on the outer wall of the semi-conductive wrapping tape 13.
  • the high-reliability, flexible, torsion-resistant low-voltage cable 10 provided above has the technical effect of being reliable and capable of realizing leakage detection.
  • the conductor 11 is protected by the insulating layer 12, and the semiconductive tape 13 is wrapped around the outer wall of the insulating layer 12 to form a monitoring layer. Since the monitoring layer is connected by wrapping, the monitoring layer can fully cover the outer wall surface of the insulating layer 12 .
  • the metal braid layer 14 is arranged on the outer wall of the semi-conductive wrapping tape 13. The metal braid layer improves the torsion and tensile resistance of the cable on the one hand, and can also perform leakage detection through the metal braid layer.
  • the conductor 11 When the insulating layer 12 is damaged After that, the conductor 11 will leak, and the current will be conducted to the conductive metal wire in the metal braid layer 14 through the semi-conductive wrapping tape 13.
  • the metal braid layer 14 By connecting the conductive metal wire in the metal braid layer 14 with the leakage protection device, the metal braid layer 14 The conductive metal wire in can transmit the leakage signal to the leakage protection device to realize the operation of reminding or power-off, thereby ensuring the safety and reliability of the high-reliability flexible torsion-resistant low-voltage cable 10.
  • the conductor 11 in this embodiment is a Category 6 super soft copper conductor 11. Its single wire is tin-plated in this embodiment, and the diameter of the conductor single wire is 0.08mm, and the outermost layer is twisted. The pitch diameter ratio is 8 times, which ensures the super-flexibility of the high-reliability, flexible, torsion-resistant low-voltage cable 10.
  • the single wire in the super six super soft copper conductor 11 may not be tinned, and the single wire diameter may be 0.05mm-0.5mm, the outermost stranded pitch diameter ratio only needs to be no more than 12 times.
  • other standard conductors 11 may also be used, such as Category 5, Category 5 or Category 6 conductors 11, etc.
  • the semi-conductive tape 13 in this embodiment forms a monitoring layer on the outer wall of the insulating layer 12, and the tape material of the semi-conductive tape 13 is a non-woven material with semi-conductive properties in this embodiment.
  • the wrapping material of the semi-conductive wrapping tape 13 may also be nylon wrapping tape or cable paper with semi-conductive properties.
  • the surface resistivity of the monitoring layer should be less than 1500 ohms, and the wrapping rate should be one-quarter to one-half, such as one-third.
  • the material of the insulating layer 12 in this embodiment is a super soft TPE thermoplastic elastomer (TPE: Thermoplastic Elastomer), which has high strength and high resilience.
  • TPE thermoplastic elastomer
  • the insulating layer 12 can also be made of other insulating materials, such as polyethylene, cross-linked polyethylene, polyvinyl chloride, polypropylene, polyolefin, fluoroplastics, nylon, or ethylene-propylene rubber. It should be noted that the Shore A hardness of the insulating layer 12 in this embodiment is 72 ⁇ 3.
  • the metal braid 14 in this embodiment is woven by a mixture of copper wires and high-performance fibers.
  • the leakage signal is transmitted through copper wires, and the high-performance fibers are used to improve The torsion and tensile properties of the cable.
  • the metal woven mesh can also be woven by mixing other metal wires and fibers that can perform signal transmission, for example, mixing silver wires and fibers.
  • the conductor 11, insulating layer 12, monitoring layer (semi-conductive tape 13) and metal braided layer 14 provided above make the highly reliable, flexible and torsion resistant low-voltage cable 10 provided in this embodiment have high flexibility, high tensile strength, torsion resistance, The characteristics of high reliability and leakage detection can meet the requirements of the industry for cables.
  • the wrapping joint of the semi-conductive wrapping tape 13 is fixed by a semi-conductive tape.
  • the semi-conductive tape 13 can be fixed on the insulating layer 12 by the fixing method of the semi-conductive tape, which can ensure the integrity of the semi-conductive tape 13 and the insulating layer 12, and also ensure the monitoring of the semi-conductive tape 13 The electrical conductivity of the layer throughout the cable.
  • the wrapping joint of the semi-conductive tape 13 can also be bonded by semi-conductive glue, for example, bonded by epoxy resin glue of the semiconductor 11.
  • the semi-conductive tape 13 can be bonded by hot-melt adhesive, where the hot-melt adhesive is a plastic adhesive whose physical state changes with temperature within a certain temperature range, while its chemical properties remain unchanged. It is non-toxic and tasteless, and is an environmentally friendly chemical product; by using hot-melt adhesive for bonding and fixing, the hot-melt adhesive can fill the voids of the semi-conductive tape 13, making the overall structure of the cable more compact.
  • the hot-melt adhesive is a plastic adhesive whose physical state changes with temperature within a certain temperature range, while its chemical properties remain unchanged. It is non-toxic and tasteless, and is an environmentally friendly chemical product; by using hot-melt adhesive for bonding and fixing, the hot-melt adhesive can fill the voids of the semi-conductive tape 13, making the overall structure of the cable more compact.
  • the surface of the conductive metal wire in the metal braid layer 14 is tin-plated.
  • the surface of the conductive metal wire is plated with tin to improve its corrosion resistance and improve its solderability.
  • the metal wire in the metal braided layer 14 in this embodiment is a copper wire, in other specific embodiments, it can also be other metal wires that can transmit signals.
  • the surface can also be non-tinned.
  • the high-reliability, flexible, torsion-resistant low-voltage cable 10 further includes an outer sheath 15, see FIG. 2, which shows the specific structure of another high-reliability, flexible, torsion-resistant low-voltage cable 10 in this embodiment.
  • the outer sheath 15 is arranged on the outer wall of the metal braided layer 14.
  • the outer sheath 15 can be used as a protective layer to protect the outside of the cable, so that the cable can be used in various harsh environments.
  • the material of the outer sheath 15 in this embodiment is Thermoplastic Polyurethanes (TPU, TPU: Thermoplastic Polyurethanes).
  • TPU Thermoplastic Polyurethanes
  • the thermoplastic polyurethane elastomer has the characteristics of super abrasion resistance, scratch resistance, high strength, low temperature resistance, flame retardancy, grease resistance and acid-base chemicals.
  • the thermoplastic polyurethane elastomer can ensure that the cable can be used in various harsh environments. Used in.
  • the material of the outer sheath 15 can also be other materials, such as polyvinyl chloride, polyethylene, or neoprene.
  • the high-reliability, flexible and torsion-resistant low-voltage cable 10 provided by this embodiment has a conductor in the cable with a monofilament diameter and a stranded pitch diameter ratio that can ensure the flexibility of the cable; the monitoring layer is wound with a semi-conductive tape The package is formed to achieve full coverage of the monitoring layer; the metal braid is woven with a mixture of copper wires and high-performance fibers. On the one hand, the copper wires realize the transmission of leakage signals.
  • the leakage protection device is used to ensure that the equipment is The safety and reliability of the surrounding environment, on the other hand, the high-performance fiber in it improves the torsion and tensile resistance of the cable; the selection of super wear resistance, scratch resistance, high strength, and excellent low temperature resistance, flame retardancy,
  • the thermoplastic polyurethane elastomer material that is resistant to grease and acid and alkali chemicals makes the cable can be used in various harsh environments.
  • this embodiment also provides a cable manufacturing method 20, please refer to FIG. 3, which is a schematic diagram of a cable manufacturing method 20 in this embodiment.
  • the production method 20 includes:
  • the metal braid is arranged on the outer wall of the semi-conductive tape.
  • the foregoing provides a method for manufacturing a cable capable of reliably realizing leakage detection.
  • the outer wall of the conductor is provided with an insulating layer for insulation isolation, and the semi-conductive tape is wrapped around the outer wall of the insulating layer to form a monitoring layer. Since the monitoring layer is connected by wrapping, Therefore, the monitoring layer can fully cover the outer wall surface of the insulating layer.
  • the metal braid is arranged on the outer wall of the semi-conductive tape, and the metal braid is used to improve the torsion and tensile resistance of the cable on the one hand, and on the other hand, the metal braid can also be used for leakage detection.
  • the conductor when the insulating layer is damaged, The conductor will leak, and the current will be conducted to the conductive metal wire in the metal braid through the semi-conductive tape.
  • the conductive metal wire in the metal braid By connecting the conductive metal wire in the metal braid with the leakage protection device, the conductive metal wire in the metal braid The leakage signal can be transmitted to the leakage protection device to realize the operation of reminding or power off, thereby ensuring the safety and reliability of the cable.
  • the conductor is superfinely stranded Super Category 6 super soft copper conductor.
  • the specific production method is the copper wire stranding process
  • the twisting method is the tape withdrawal
  • the twisted cage stranding machine is twisted, and the tension of each pay-off reel is calibrated to be the same before starting up, which can ensure that the pay-off tension of each pay-off reel is basically the same during the stranding process.
  • the outer stranded pitch diameter ratio is not more than 12 times, which can ensure the conductor has high flexibility and bending performance.
  • the single wire in the super six super soft copper conductor in the process of making the conductor, is tin-plated, the conductor single wire diameter is 0.08mm, and the outermost stranded pitch diameter ratio is 8 times.
  • the single wire in the super six super soft copper conductor may not be tinned, and the diameter of the single wire may be 0.05mm-0.5mm, such as 0.09mm, 0.15mm, 0.20mm or 0.25mm, etc., the outermost The pitch diameter ratio of the layer stranding only needs to be no more than 12 times, such as 6 times or 7 times.
  • other standard conductors may also be used, such as Category 5, Category 5 or Category 6 conductors.
  • the step of disposing the insulating layer on the outer wall of the conductor further includes the following steps:
  • the insulating material is extruded on the conductor by an extruder to form an insulating layer.
  • the extruder can at least heat and plasticize the insulating material and evenly squeeze it on the conductor, so as to ensure that the outer wall of the conductor can completely cover the insulating layer.
  • the insulating material is an ultra-soft TPE thermoplastic elastomer (TPE: Thermoplastic Elastomer).
  • TPE thermoplastic elastomer
  • the insulating material (TPE in this example) is heated, plasticized, melted and evenly extruded on the conductor by an extruder.
  • a semi-extrusion tube mold is used.
  • the temperature range of each section of the extruder is 170°C to 200°C.
  • the temperature range of the mold is 210°C ⁇ 230°C
  • the wire core is tested under 15kV power frequency spark voltage after extrusion.
  • each section of the extruder refers to the feeding section, the plasticizing section and the homogenizing section. When the temperature of the feeding section, the plasticizing section and the homogenizing section are at 170°C ⁇ 200°C, the feeding section, plasticizing section The temperature of the section and the homogenization section are gradually increased.
  • the insulating material can also be extruded through other tube extrusion molds.
  • the overlap rate is one third, and the tape material of the semi-conductive tape is in this embodiment
  • the semi-conductive tape forms a monitoring layer on the outer wall of the insulating layer, and the surface resistivity of the monitoring layer should be less than 1500 ohms.
  • the tape material of the semi-conductive tape may also be nylon tape or cable paper with semi-conductive properties.
  • the wrapping rate is one quarter to one half.
  • the method further includes:
  • the semi-conductive tape can be fixed on the insulating layer through the fixing method of the semi-conductive tape, which can ensure the integrity of the semi-conductive tape and the insulating layer, and also ensure that the monitoring layer composed of the semi-conductive tape is in the entire cable The conductive properties.
  • the method further includes:
  • Copper wires and high-performance fibers are braided by a braiding machine to form a metal braid.
  • the total number of weaving spindles is 8 to 36 spindles, and the number of copper wire spindles accounts for 0-1/2; the copper wire can be tinned or not tinned.
  • the diameter of the monofilament is 0.1 ⁇ 0.4mm, the weaving angle is 30 ⁇ 60°; the strength of each high-strength fiber is not less than 300N.
  • the total number of weaving spindles is 16, and the number of copper wire spindles accounts for one half.
  • the copper wire in the metal braid can be replaced by other metal wires capable of signal transmission, such as silver wires.
  • the manufacturing method 20 further includes the following steps (see FIG. 4, which is a schematic diagram of another manufacturing method 20 in this embodiment):
  • thermoplastic polyurethane elastomer is extruded on the metal braided layer by an extruder to form an outer sheath (shown in the figure: the outer sheath is arranged on the outer wall of the metal braided layer).
  • the outer sheath 15 can serve as a protective layer to protect the outside of the cable, so that the cable can be used in various harsh environments.
  • the outer sheath is formed by extruding the thermoplastic polyurethane elastomer on the metal braid through an extruder. Since the outer sheath is formed by extruding by the extruder, the outer sheath can be evenly and completely covered on the metal The outer wall of the braided layer.
  • the outer sheath is made of thermoplastic polyurethane elastomer
  • the outer sheath has super wear resistance, scratch resistance, high strength, and excellent low temperature resistance, flame resistance, grease and acid resistance
  • the performance of alkali chemicals so the cable can be used in various harsh environments under the protection of the outer sheath.
  • thermoplastic polyurethane elastomers TPU, TPU: Thermoplastic polyurethanes
  • TPU, TPU: Thermoplastic polyurethanes have the characteristics of super abrasion resistance, scratch resistance, high strength, low temperature resistance, flame retardancy, resistance to grease and acid and alkali chemicals. Polyurethane elastomer can ensure that the cable can be used in various harsh environments.
  • each section of the extruder refers to the feeding section, plasticizing section and homogenizing section.
  • the temperature of the feeding section, plasticizing section and homogenizing section is under the condition of 150°C ⁇ 200°C, the feeding section, plasticizing section The temperature of the section and the homogenization section are gradually increased.
  • the cable manufactured through the above steps enables the conductors in the cable to have a monofilament diameter and a stranded pitch diameter ratio that can ensure the flexibility of the cable; since the monitoring layer is formed by wrapping a semi-conductive tape, it can Realize the full coverage of the conductor by the monitoring layer; the metal braid is woven by a mixture of copper wire and high-performance fiber.
  • the copper wire realizes the transmission of leakage signals. Once the insulation is broken, the copper of the metal braid The wire is matched with the leakage protection device to ensure the safety and reliability of the equipment and the surrounding environment.
  • the high-performance fiber in the metal braid improves the torsion and tensile performance of the cable; through the selection of super wear resistance, scratch resistance and high strength
  • the thermoplastic polyurethane elastomer material with excellent low temperature resistance, flame retardancy, grease resistance and acid and alkali chemical properties is the outer sheath.
  • the outer sheath 15 can be used as a protective layer to protect the outside of the cable, so that the cable It can be used in various harsh environments.
  • the embodiments of the present application provide a high-reliability, flexible, torsion-resistant low-voltage cable and a manufacturing method thereof.
  • the torsion and tensile performance of the cable can be improved through the semi-conductive tape and the metal braid, and the leakage detection can be performed efficiently.

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Abstract

一种高可靠柔性抗扭低压电缆及其制作方法，包括导体（11）、绝缘层（12）、半导电包带（13）以及金属编织层（14）。绝缘层（12）设置于导体（11）的外壁。半导电包带（13）绕包于绝缘层（12）的外壁。金属编织层（14）设置于半导电包带（13）的外壁。电缆以及通过该制作方法制造的电缆能够高效地进行漏电检测。

Description

一种高可靠柔性抗扭低压电缆及其制作方法
相关申请的交叉引用
本申请要求于2019年05月13日提交中国专利局的申请号为201910395851.3、名称为“一种高可靠柔性抗扭低压电缆及其制作方法”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请涉及电缆技术领域，具体而言，涉及一种高可靠柔性抗扭低压电缆及其制作方法。
背景技术
针对工业领域使用的移动电缆，比如焊机电缆，在使用时电缆需要经受拖拽、弯曲以及扭转等操作，由于电缆自身材料老化的原因，以及在外界机械应力的作用下，使得电缆在长时间使用过程中，容易造成绝缘破皮的现象。
目前，常规的针对绝缘破皮进行检测的方法为人工目测，由于人工目测检测效率低，且漏检率较高，造成很多情况下绝缘破皮无法及时发现，而且当绝缘破皮后，会存在不同程度的漏电情况，因此会导致设备存在安全隐患，使得操作工人的安全性无保障。
申请内容
本申请提供了一种高可靠柔性抗扭低压电缆及其制作方法，该电缆以及通过该制作方法制造的电缆至少能够实现高效地进行漏电检测的技术效果。
本申请提供了一种高可靠柔性抗扭低压电缆，包括导体、绝缘层、半导电包带以及金属编织层。绝缘层设置于导体的外壁。半导电包带绕包于 绝缘层的外壁。金属编织层设置于半导电包带的外壁。
在上述方案中，本申请提供一种可靠性实现漏电检测的电缆，至少能够实现以下技术效果：其中，导体通过绝缘层保护，半导电包带绕包于绝缘层的外壁构成监视层，由于监视层是通过绕包连接的，故监视层能够全面的覆盖绝缘层的外壁表面。金属编织层设置于半导电包带的外壁，利用金属编织层一方面提高了电缆的抗扭抗拉性能，另一方面还可以通过金属编织层进行漏电检测，其中，当绝缘层破损后，导体会发生漏电的情况，电流会通过半导电包带传导至金属编织层中的导电金属丝，通过将金属编织层中的导电金属丝与漏电保护装置连接，使得金属编织层中的导电金属丝能够将漏电信号传输至漏电保护装置中以实现提醒或者断电的操作，从而确保电缆的安全可靠性。
可选地，半导电包带的绕包接头处通过半导电胶布固定。
上述方案中，技术效果至少包括：通过半导电胶布使得半导电包带固定在绝缘层上，能够保证半导电包带与绝缘层的整体性，同时也保证了半导电包带构成的监视层在整个电缆中的导电特性。
可选地，半导电包带的绕包接头处通过半导电特性的胶水粘接固定。
上述方案中，通过半导电特性的胶水粘使得半导电包带固定在绝缘层上，保证半导电包带与绝缘层的整体性，同时也保证了半导电包带构成的监视层在整个电缆中的导电特性。
可选地，金属编织层中的导电金属丝表面镀锡。
上述方案中，技术效果至少包括：通过在导电金属丝的表面镀锡以提高其耐腐蚀性能，同时还可以提高导电金属丝的可焊性能。
可选地，电缆还包括外护套，外护套设置于金属编织层的外壁。
上述方案中，技术效果至少包括：通过在金属编织层的外壁设置外护 套，使得电缆能够在外护套的保护下，能够在各种恶劣的环境中使用。
可选地，导体采用超六类超软铜导体；
导体的单线外表面镀锡。
可选地，半导电包带的包带材料为具有半导电性质的无纺布。
可选地，半导电包带在所述绝缘层的外壁构成了监视层，所述监视层的表面电阻率小于1500欧姆。
可选地，监视层的绕包搭盖率为四分之一至二分之一。
可选地，金属编织层包括混合编织的铜丝和高性能纤维。
本申请提供了一种电缆的制作方法，该制作方法包括：
将绝缘层设置于导体的外壁；
将半导电包带绕包于绝缘层的外壁；
将金属编织层设置于半导电包带的外壁。
在上述方案中，本申请提供一种能够制造实现漏电检测的电缆的方法，其中，至少能够实现以下技术效果：将导体的外壁设置一层绝缘层进行绝缘隔离，通过将半导电包带绕包于绝缘层的外壁以构成监视层，由于监视层是通过绕包连接的，故监视层能够全面的覆盖绝缘层的外壁表面。将金属编织层设置于半导电包带的外壁，利用金属编织层一方面提高了电缆的抗扭抗拉性能，另一方面还可以通过金属编织层进行漏电检测，其中，当绝缘层破损后，导体会发生漏电的情况，电流会通过半导电包带传导至金属编织层中的导电金属丝，通过将金属编织层中的导电金属丝与漏电保护装置连接，使得金属编织层中的导电金属丝能够将漏电信号传输至漏电保护装置中以实现提醒或者断电的操作，从而确保电缆的安全可靠性。
可选地，在将绝缘层设置于导体的外壁的步骤中，还包括：
通过挤塑机将绝缘料挤包于导体上以构成绝缘层。
上述方案中，技术效果至少包括：通过挤塑机能够将绝缘料加热塑化并均匀地挤包在导体上，以保证导体的外壁能够平整完全地覆盖绝缘层。
可选地，通过挤塑机将绝缘料挤包于所述导体上的步骤还包括：
通过挤塑机将绝缘料加热塑化后均匀地挤包在导体上。
可选地，绝缘料加热塑化的步骤还包括：
挤塑机采用半挤管式模具，挤出机各段的温度范围170℃-200℃，机头模具的温度范围210℃-230℃。
可选地，在将半导电包带绕包于绝缘层的外壁的步骤中，还包括：
通过半导电胶布将半导电包带的绕包接头扎紧。
上述方案中，技术效果至少包括：通过半导电胶布使得半导电包带固定在绝缘层上，能够保证半导电包带与绝缘层的整体性，同时也保证了半导电包带构成的监视层在整个电缆中的导电特性。
可选地，在将金属编织层设置于半导电包带的外壁的步骤中，还包括：
通过编织机编织铜丝和高性能纤维以构成金属编织层。
可选地，制作方法还包括：
通过挤塑机将热塑性聚氨酯弹性体挤包于金属编织层上以构成外护套。
上述方案中，技术效果至少包括：通过在金属编织层的外壁设置外护套，使得电缆能够在外护套的保护下，能够在各种恶劣的环境中使用。其中，外护套是通过挤塑机将热塑性聚氨酯弹性体挤包于金属编织层上形成的，由于外护套是通过挤塑机挤塑构成，使得外护套能够均匀地完整地覆盖于金属编织层的外壁，同时，由于外护套的原料为热塑性聚氨酯弹性体，故外护套具有超耐磨、耐刮檫、高强度以及具有优异的耐低温性能、阻燃性能、耐油脂及酸碱化学品的性能，故电缆能够在外护套的保护下，在各 种恶劣的环境中使用。
附图说明
为了更清楚地说明本申请实施例的技术方案，下面将对实施例中所需要使用的附图作简单地介绍，应当理解，以下附图仅示出了本申请的某些实施例，因此不应被看作是对范围的限定，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他相关的附图。
图1为本申请实施例中一种电缆的具体结构；
图2为本申请实施例中另一种电缆的具体结构；
图3为本申请实施例中一种电缆的制作方法的示意图；
图4为本申请实施例中另一种电缆的制作方法的示意图。
图标：10-高可靠柔性抗扭低压电缆；11-导体；12-绝缘层；13-半导电包带；14-金属编织层；15-外护套；20-制作方法。
具体实施方式
为使本申请实施例的目的、技术方案和优点更加清楚，下面将结合本申请实施例中的附图，对本申请实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例是本申请一部分实施例，而不是全部的实施例。通常在此处附图中描述和示出的本申请实施例的组件可以以各种不同的配置来布置和设计。
因此，以下对在附图中提供的本申请的实施例的详细描述并非旨在限制要求保护的本申请的范围，而是仅仅表示本申请的选定实施例。基于本申请中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。
应注意到：相似的标号和字母在下面的附图中表示类似项，因此，一旦某一项在一个附图中被定义，则在随后的附图中不需要对其进行进一步 定义和解释。
在本申请实施例的描述中，需要理解的是，术语“中心”、“上”、“下”、“左”、“右”、“竖直”、“水平”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，或者是该申请产品使用时惯常摆放的方位或位置关系，或者是本领域技术人员惯常理解的方位或位置关系，仅是为了便于描述本申请和简化描述，而不是指示或暗示所指的设备或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本申请的限制。
在本申请实施例的描述中，还需要说明的是，除非另有明确的规定和限定，术语“设置”、“安装”、“相连”、“连接”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体地连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通。对于本领域的普通技术人员而言，可以具体情况理解上述术语在本申请中的具体含义。
需要说明的是，在不冲突的情况下，本申请中的实施例及实施例中的特征可以相互组合。
下面将结合附图，对本申请中的技术方案进行描述。
本实施例提供一种电缆，该电缆能够高效地进行漏电检测。
请参考图1，图1示出了本实施例提供的一种高可靠柔性抗扭低压电缆10的具体结构。
高可靠柔性抗扭低压电缆10包括导体11、绝缘层12、半导电包带13以及金属编织层14。绝缘层12设置于导体11的外壁。半导电包带13绕包于绝缘层12的外壁。金属编织层14设置于半导电包带13的外壁。
上述提供的高可靠柔性抗扭低压电缆10具有可靠、能够实现漏电检测的技术效果。其中，导体11通过绝缘层12保护，半导电包带13绕包于绝 缘层12的外壁构成监视层，由于监视层是通过绕包连接的，故监视层能够全面的覆盖绝缘层12的外壁表面。金属编织层14设置于半导电包带13的外壁，利用金属编织层一方面提高了电缆的抗扭抗拉性能，另一方面还可以通过金属编织层进行漏电检测，其中，当绝缘层12破损后，导体11会发生漏电，电流会通过半导电包带13传导至金属编织层14中的导电金属丝，通过将金属编织层14中的导电金属丝与漏电保护装置连接，使得金属编织层14中的导电金属丝能够将漏电信号传输至漏电保护装置中以实现提醒或者断电的操作，从而确保高可靠柔性抗扭低压电缆10的安全可靠性。
其中，需要说明的是，本实施例中导体11采用的是超六类超软铜导体11，其单线在本实施例中采用镀锡，并且导体单线的直径为0.08mm，最外层绞合节径比为8倍，保证了高可靠柔性抗扭低压电缆10的超柔性，在其他具体实施方式中，超六类超软铜导体11中的单线也可以不采用镀锡，单线直径可以为0.05mm-0.5mm，最外层绞合节径比只需要满足不大于12倍即可。需要说明的是，在其他具体实施方式中，亦可以采用其他标准的导体11，例如五类、超五类或六类导体11等。
同时，需要说明的是，本实施例中的半导电包带13在绝缘层12的外壁构成了监视层，半导电包带13的包带材料在本实施例中为具有半导电性质的无纺布，在其他具体实施方式中，半导电包带13的包带材料还可以为具有半导电性质的尼龙包带或者电缆纸等。同时需要说明的是，监视层的表面电阻率应小于1500欧姆，绕包搭盖率为四分之一至二分之一，例如三分之一等。
同时，需要说明的是，本实施例中的绝缘层12的材料为超软TPE热塑性弹性体(TPE：Thermoplastic Elastomer)，其具有高强度和高回弹性。在其他具体实施方式中，绝缘层12亦可通过其他绝缘材料制成，例如聚乙 烯、交联聚乙烯、聚氯乙烯、聚丙烯、聚烯烃、氟塑料、尼龙或者乙丙橡胶等。其中，需要说明的是本实施例中的绝缘层12的邵尔A硬度为72±3。
同时，需要说明的是，本实施例中的金属编织层14是通过铜丝和高性能纤维混合编织而成，在本实施例中是通过铜丝进行漏电信号的传输，通过高性能纤维以提高电缆的抗扭抗拉性能。另外，在其他具体实施方式中，金属编织网还可以通过其他可进行信号传输的金属丝与纤维进行混合编织，例如银丝与纤维混合编织等。
通过上述提供的导体11、绝缘层12、监视层(半导电包带13)以及金属编织层14使得本实施例提供的高可靠柔性抗扭低压电缆10具有高柔性、高抗拉、抗扭、高可靠性以及可漏电检测的特点，能够满足工业上对电缆的需求。
可选地，半导电包带13的绕包接头处通过半导电胶布固定。
其中，通过半导电胶布的固定方式能够使得半导电包带13固定在绝缘层12上，能够保证半导电包带13与绝缘层12的整体性，同时也保证了半导电包带13构成的监视层在整个电缆中的导电特性。
需要说明的是，在其他具体实施方式中，半导电包带13的绕包接头处还可以通过具有半导电特性的胶水进行粘接，例如通过半导体11环氧树脂胶水进行粘接等。
或者，半导电包带13可以采用热熔胶进行粘接，其中，热熔胶是一种可塑性的粘合剂，在一定温度范围内其物理状态随温度改变而改变，而化学特性不变，其无毒无味，属环保型化学产品；通过利用热熔胶粘接固定，能够使得热熔胶对半导电包带13的空隙进行填充，使得电缆的整体结构更加紧凑。
可选地，金属编织层14中的导电金属丝表面镀锡。通过在导电金属丝 的表面镀锡以提高其耐腐蚀性能，同时提高了其可焊性能。同时，需要说明的是，在其他具体实施方式中，金属编织层14中的金属丝(在本实施例中为铜丝，在其他具体实施方式中，还可以为其他可以进行信号传输的金属丝)的表面还可以采用不镀锡。
可选地，高可靠柔性抗扭低压电缆10还包括外护套15，参见图2，图2示出了本实施例中另一种高可靠柔性抗扭低压电缆10的具体结构。
外护套15设置于金属编织层14的外壁。
其中，通过在金属编织层14的外壁设置外护套15，外护套15能够作为防护层对电缆的外部进行保护，以使电缆能够在各种恶劣的环境中使用。
需要说明的是，本实施例中的外护套15的材质为热塑性聚氨酯弹性体(TPU，TPU：Thermoplastic polyurethanes)。其中，热塑性聚氨酯弹性体具有超耐磨、耐刮檫、高强度、耐低温性能、阻燃性能、耐油脂及酸碱化学品的特性，热塑性聚氨酯弹性体能够保证电缆可以在各种恶劣的环境中使用。同时需要说明的是，在其他具体实施方式中，外护套15的材质还可以为其他材质，例如：聚氯乙烯、聚乙烯或氯丁橡胶等。
如图1及图2所示，本实施例提供的高可靠柔性抗扭低压电缆10，电缆中导体具有能够确保电缆柔软性的单丝直径和束绞节径比；监视层采用半导电包带绕包形成，实现监视层的全覆盖；金属编织层采用铜丝和高性能纤维混合编织而成，一方面，铜丝实现了漏电信号的传输，一旦绝缘破皮，配合漏电保护装置，确保设备与周围环境的安全可靠性，另一方面，其中的高性能纤维提高了电缆的抗扭抗拉性能；选用超耐磨、耐刮檫、高强度，同时具有优异的耐低温性能、阻燃性能、耐油脂及酸碱化学品的性能的热塑性聚氨酯弹性体材料，使得电缆可以在各种恶劣环境中使用。
需要说明的是，本实施例还提供一种电缆的制作方法20，请参见图3， 图3为本实施例中一种电缆的制作方法20的示意图。
该制作方法20包括：
将绝缘层设置于导体的外壁；
将半导电包带绕包于绝缘层的外壁；
将金属编织层设置于半导电包带的外壁。
其中，上述提供了一种能够制造可靠性实现漏电检测的电缆的方法。其中，至少能够实现以下技术效果：将导体的外壁设置一层绝缘层进行绝缘隔离，通过将半导电包带绕包于绝缘层的外壁以构成监视层，由于监视层是通过绕包连接的，故监视层能够全面的覆盖绝缘层的外壁表面。将金属编织层设置于半导电包带的外壁，利用金属编织层一方面提高了电缆的抗扭抗拉性能，另一方面还可以通过金属编织层进行漏电检测，其中，当绝缘层破损后，导体会发生漏电的情况，电流会通过半导电包带传导至金属编织层中的导电金属丝，通过将金属编织层中的导电金属丝与漏电保护装置连接，使得金属编织层中的导电金属丝能够将漏电信号传输至漏电保护装置中以实现提醒或者断电的操作，从而确保电缆的安全可靠性。
需要说明的是，上述提供的制作方法20中，导体采用的是超精细绞合的超六类超软铜导体，具体地生产方式是采用铜丝束绞工艺，绞合的方式是采用带退扭的笼式绞线机绞制，开机前通过校准各放线盘的张力一致，进而能够确保绞线过程中各放线盘的放线张力基本一致，通过严格控制束绞节径比，使得外层绞合节径比不大于12倍，进而能够确保导体具有较高的柔韧弯曲性能。同时，需要说明的是，在本实施例中，在制作导体的过程中，超六类超软铜导体中的单线采用镀锡，导体单线直径为0.08mm，最外层绞合节径比为8倍。在其他具体实施方式中，超六类超软铜导体中的单线也可以不采用镀锡，单线直径可以为0.05mm-0.5mm，例如0.09mm、 0.15mm、0.20mm或0.25mm等，最外层绞合节径比只需要满足不大于12倍即可，例如6倍或7倍等。需要说明的是，在其他具体实施方式中，亦可以采用其他标准的导体，例如五类、超五类或六类导体等。
可选地，在将绝缘层设置于导体的外壁的步骤中，还包括以下步骤：
通过挤塑机将绝缘料挤包于导体上以构成绝缘层。
上述方案中，通过挤塑机，至少能够实现将绝缘料加热塑化并均匀地挤包在导体上，以保证导体的外壁能够平整完全地覆盖绝缘层。
其中，本实施例中，绝缘料为超软TPE热塑性弹性体(TPE：Thermoplastic Elastomer)。通过挤塑机将绝缘料(本实施例中为TPE)加热塑化熔融均匀挤包在导体上，采用半挤管式模具，挤出机各段的温度范围为170℃～200℃，机头模具的温度范围为210℃～230℃，挤出后线芯在线15kV工频火花电压下进行检测。其中，挤出机各段是指，加料段、塑化段和均化段，当加料段、塑化段和均化段的温度在170℃～200℃的条件下时，加料段、塑化段和均化段的温度是逐渐增加的。
同时，需要说明的是，在其他具体实施方式中，绝缘料还可以通过其他挤管式模具进行挤包。
可选地，本实施例中，在将半导电包带绕包于绝缘层的外壁的步骤中，搭盖率为三分之一，同时，半导电包带的包带材料在本实施例中为具有半导电性质的无纺布，半导电包带在绝缘层的外壁构成了监视层，监视层的表面电阻率应小于1500欧姆。在其他具体实施方式中，半导电包带的包带材料还可以为具有半导电性质的尼龙包带或者电缆纸等。绕包搭盖率为四分之一至二分之一。
可选地，在将半导电包带绕包于绝缘层的外壁的步骤中，还包括：
通过半导电胶布将半导电包带的绕包接头扎紧。
其中，通过半导电胶布的固定方式能够使得半导电包带固定在绝缘层上，能够保证半导电包带与绝缘层的整体性，同时也保证了半导电包带构成的监视层在整个电缆中的导电特性。
可选地，在将金属编织层设置于半导电包带的外壁的步骤中，还包括：
通过编织机编织铜丝和高性能纤维以构成金属编织层。
其中，需要说明的是，通过在编织机上生产实现，编织总锭数为8锭-36锭，铜丝锭数占比0-1/2；铜丝可以采用镀锡，也可以不采用镀锡，单丝直径为0.1～0.4mm，编织角度为30～60°；每锭高强度纤维的强度不小于300N。在本实施例中，编织总锭数为16锭，铜丝锭数占比二分之一。同时，需要说明的是，在其他具体实施方式中，金属编织层中的铜丝可由其他能够进行信号传输的金属丝代替，例如银丝等。
需要说明的是，制作方法20还包括以下步骤(可参见图4，图4为本实施例中另一种制作方法20的示意图)：
通过挤塑机将热塑性聚氨酯弹性体挤包于金属编织层上以构成外护套(图中示为：将外护套设置于金属编织层的外壁)。
通过在金属编织层的外壁设置外护套，外护套15能够作为防护层对电缆的外部进行保护，以使电缆能够在各种恶劣的环境中使用。其中，外护套是通过挤塑机将热塑性聚氨酯弹性体挤包于金属编织层上形成的，由于外护套是通过挤塑机挤塑构成，使得外护套能够均匀地完整地覆盖于金属编织层的外壁，同时，由于外护套的原料为热塑性聚氨酯弹性体，故外护套具有超耐磨、耐刮檫、高强度以及具有优异的耐低温性能、阻燃性能、耐油脂及酸碱化学品的性能，故电缆能够在外护套的保护下，在各种恶劣的环境中使用。其中，需要说明的是，热塑性聚氨酯弹性体(TPU，TPU：Thermoplastic polyurethanes)具有超耐磨、耐刮檫、高强度、耐低温性 能、阻燃性能、耐油脂及酸碱化学品的特性，热塑性聚氨酯弹性体能够保证电缆可以在各种恶劣的环境中使用。
其中，通过挤塑机将热塑性聚氨酯弹性体加热塑化熔融均匀挤包在导体上，采用半挤管式模具的基础上，挤出机各段的温度范围为150℃～200℃，机头模具的温度范围为190℃～200℃，挤出后，成品经受3.5kV 5min工频电压下进行试验。其中，挤出机各段是指，加料段、塑化段和均化段，当加料段、塑化段和均化段的温度在150℃～200℃的条件下时，加料段、塑化段和均化段的温度是逐渐增加的。
需要说明的是，通过上述步骤来制造得到的电缆，使得电缆中的导体具有能够确保电缆柔软性的单丝直径和束绞节径比；由于监视层是采用半导电包带绕包形成，进而能够实现监视层对导体的全覆盖；金属编织层采用铜丝和高性能纤维混合编织而成，一方面，铜丝实现了漏电信号的传输，一旦绝缘出现破皮的情况时，金属编织层的铜丝配合漏电保护装置，确保设备与周围环境的安全可靠性，另一方面，金属编织层其中的高性能纤维提高了电缆的抗扭抗拉性能；通过选用超耐磨、耐刮檫以及高强度，同时具有优异的耐低温性能、阻燃性能、耐油脂及酸碱化学品的性能的热塑性聚氨酯弹性体材料为外护套，外护套15能够作为防护层对电缆的外部进行保护，使得电缆可以在各种恶劣环境中使用。
以上所述仅为本申请的优选实施例而已，并不用于限制本申请，对于本领域的技术人员来说，本申请可以有各种更改和变化。凡在本申请的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本申请的保护范围之内。
工业实用性
本申请实施例提供的一种高可靠柔性抗扭低压电缆及其制作方法，通过半导电包带和金属编织层能够提高电缆的抗扭抗拉性能，能够高效地进行漏电检测。

Claims (18)

  1. 一种高可靠柔性抗扭低压电缆，其特征在于，包括：
    导体；
    绝缘层，所述绝缘层设置于所述导体的外壁；
    半导电包带，所述半导电包带绕包于所述绝缘层的外壁；以及
    金属编织层，所述金属编织层设置于所述半导电包带的外壁。
  2. 根据权利要求1所述的高可靠柔性抗扭低压电缆，其特征在于，
    所述半导电包带的绕包接头处通过半导电胶布固定。
  3. 根据权利要求1所述的高可靠柔性抗扭低压电缆，其特征在于，
    所述半导电包带的绕包接头处通过半导电特性的胶水粘接固定。
  4. 根据权利要求1-3任意一项所述的高可靠柔性抗扭低压电缆，其特征在于，
    所述金属编织层中的导电金属丝表面镀锡。
  5. 根据权利要求1-4任意一项所述的高可靠柔性抗扭低压电缆，其特征在于，
    所述高可靠柔性抗扭低压电缆还包括外护套，所述外护套设置于所述金属编织层的外壁。
  6. 根据权利要求1-5任意一项所述的高可靠柔性抗扭低压电缆，其特征在于，所述导体采用超六类超软铜导体；
    所述导体的单线外表面镀锡。
  7. 根据权利要求1-6任意一项所述的高可靠柔性抗扭低压电缆，其特征在于，所述半导电包带的包带材料为具有半导电性质的无纺布。
  8. 根据权利要求1-7任意一项所述的高可靠柔性抗扭低压电缆，其特征在于，所述半导电包带在所述绝缘层的外壁构成了监视层，所述监视层 的表面电阻率小于1500欧姆。
  9. 根据权利要求8所述的高可靠柔性抗扭低压电缆，其特征在于，所述监视层的绕包搭盖率为四分之一至二分之一。
  10. 根据权利要求1-9任意一项所述的高可靠柔性抗扭低压电缆，其特征在于，所述金属编织层包括混合编织的铜丝和高性能纤维。
  11. 一种电缆的制作方法，其特征在于，所述制作方法包括：
    将绝缘层设置于导体的外壁；
    将半导电包带绕包于所述绝缘层的外壁；
    将金属编织层设置于所述半导电包带的外壁。
  12. 根据权利要求11所述的制作方法，其特征在于，
    所述将绝缘层设置于所述导体的外壁包括：
    通过挤塑机将绝缘料挤包于所述导体上以构成所述绝缘层。
  13. 根据权利要求12所述的制作方法，其特征在于，所述通过挤塑机将绝缘料挤包于所述导体上的步骤还包括：
    通过挤塑机将绝缘料加热塑化后均匀地挤包在所述导体上。
  14. 根据权利要求13所述的制作方法，其特征在于，所述绝缘料加热塑化的步骤还包括：
    挤塑机采用半挤管式模具，挤出机各段的温度范围170℃-200℃，机头模具的温度范围210℃-230℃。
  15. 根据权利要求11-14任意一项所述的制作方法，其特征在于，
    所述将半导电包带绕包于所述绝缘层的外壁包括：
    通过半导电胶布将所述半导电包带的绕包接头扎紧。
  16. 根据权利要求11-15任意一项所述的制作方法，其特征在于，
    所述将金属编织层设置于所述半导电包带的外壁包括：
    通过编织机编织铜丝和高性能纤维以构成所述金属编织层。
  17. 根据权利要求11-16任意一项所述的制作方法，其特征在于，所述制作方法还包括：
    通过挤塑机将热塑性聚氨酯弹性体挤包于所述金属编织层上以构成外护套。
  18. 根据权利要求11-17任意一项所述的制作方法，其特征在于，
    所述导体是由笼式绞线机绞制而成的超六类超软铜导体，所述导体的外层绞合节径比不大于12倍。
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