Three-layer lapped insulated wire and production process thereof

Abstract

The invention relates to the technical field of insulated wires, in particular to a three-layer wrapping type insulated wire and a production process thereof, and aims to solve the problems that an existing insulated wire is insufficient in insulation performance in high-end application and a multi-layer film wrapping wire production process is tedious. Uniform and tight wrapping of the three insulating layers is achieved through the three-station wrapping machine, the conductor is preferably made of monofilament tinned copper or monofilament enameled stranded wires, the three insulating layers are transparent PPS / PET adhesive tape, pink PPS / PET adhesive tape and transparent PPS / PET adhesive tape respectively, the total thickness ranges from 18 micrometers to 25 micrometers, and any two layers can bear pulse high voltage not smaller than 3 KV. The production process comprises the steps of raw material detection, paying-off and conveying, rubber coating operation (including tension adjustment), heating treatment, strict inspection, wire storage, meter counting and the like. Wherein the rubber coating operation adopts an S-direction / Z-direction alternate winding mode, the heating treatment temperature is flexibly adjusted according to the specification and the wire speed of the insulated wire, and the three-layer lapped insulated wire has excellent insulating performance and application prospects.

Description

Technical Field

[0001] The present application belongs to the technical field of insulated wires, and in particular, relates to a three-layer wrapped insulated wire and a production process thereof. Background Art

[0002] Insulated wires are widely used in various electrical settings. In medical equipment, communication equipment, photovoltaic products, and high-frequency inductor transformers, various insulated wires are needed to achieve circuit connectivity. Existing equipment often uses enameled wires or single-layer plastic-coated insulated wires to achieve circuit connection, but for high-end transformers and power supplies, the insulation of the wires is required to be very high, and the insulation of existing insulated wires cannot meet their requirements; in addition, the production process of existing multi-layer film-coated wires is cumbersome and the production efficiency is low. Summary of the invention

[0003] The technical problem to be solved by the present invention is: to solve the deficiencies in the prior art, thereby providing a three-layer wrapped insulated wire and a production process thereof, aiming to meet higher safety specifications, achieve reinforced insulation, and at the same time simplify the production process and reduce costs.

[0004] The technical solution adopted by the present invention to solve its technical problem is:

[0005] A three-layer wrapped insulated wire production process comprises the following steps:

[0006] a. Test the appearance, outer diameter of single wire, outer diameter of twisted wire, resistance, withstand voltage and twist length of incoming materials;

[0007] b. Place the incoming conductor on the pay-off rack, pay the wire with power, and the wire passes through the first, second and third rubber coating areas in sequence, and enters the lead-in, oven, testing area, wire storage rack to the take-up area;

[0008] c. Carry out the rubber coating operation. The tape in the first rubber coating area is wound around the conductor in the S direction / Z direction under the action of the driving device. When it reaches the second rubber coating area, the tape is wound in the Z direction / S direction. When it enters the third rubber coating area, the tape is wound in the S direction / Z direction.

[0009] The tape winding tension needs to be adjusted before the winding operation begins;

[0010] d. Heat the wound product in an oven to make the hot melt layer adhere automatically;

[0011] e. Conduct inspection to remove defective wires;

[0012] f. Store wire and carry out meter counting process, and record the number of meters produced in real time.

[0013] Preferably, in the three-layer wrapped insulated wire and the production process thereof of the present invention, the tape winding tension range is 13 to 30 n / m, and the tape winding tension adjustment range is 0.5% to 35%.

[0014] Preferably, in the three-layer wrapped insulated wire and the production process thereof of the present invention, the temperature of the oven is adjusted according to the specification and wire speed of the insulated wire, and the temperature range is 100-400°C.

[0015] Preferably, in a three-layer wrapped insulated wire production process of the present invention, the inspection step includes concave-convex detection, diameter gauge detection and spark machine detection to eliminate defective wires.

[0016] A wrapped three-layer insulated wire produced according to the above-mentioned three-layer wrapped insulated wire production process includes a conductor, and three layers of insulation layers are wrapped around the conductor in sequence, and the three insulation layers are respectively a first layer of transparent PPS / PET tape, a second layer of pink PPS / PET tape and a third layer of transparent PPS / PET tape. The total thickness of the insulation layer is 18 to 25 μm, and any two layers can withstand a safety voltage of not less than 3KV.

[0017] Preferably, in the three-layer wrapped insulated wire of the present invention, the conductor is a single-filament tinned copper wire or a single-filament enameled twisted wire.

[0018] Preferably, in the three-layer wrapped insulated wire of the present invention, the first insulating layer is transparent and has a thickness of 5-10 microns, the second insulating layer is pink, and the third insulating layer is transparent.

[0019] Preferably, in the three-layer wrapped insulated wire of the present invention, the total thickness of the three insulating layers is only 18-25 μm.

[0020] The beneficial effects of the present invention are:

[0021] (1) The wrapped three-layer insulated wire of the present invention has the advantages of high insulation strength, high temperature resistance, and a safety voltage of 3KV between any two layers. It meets the B / F grade heat resistance requirements, improves the coupling between coils, and helps to improve the performance of the equipment;

[0022] (2) Since the insulating wire coating of the present invention can be stripped, the three-layer structure formed by welding will not cause the risk of integration. At the same time, it also has a coating strength that can withstand high-speed winding in an automatic winding machine and adapt to the safety standards of transformers and various safety products;

[0023] (3) The production process of the present invention is simple and efficient. By adjusting parameters such as oven temperature and tape winding tension, the production requirements of insulated wires of different specifications can be met, thereby reducing production costs and improving production efficiency.

[0024] (4) The insulated wire of the present invention does not require additional barriers, interlayer tapes and insulating tubes, thereby achieving miniaturization of the transformer, reduction of material costs and improvement of performance, and has broad application prospects and market value. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The technical solution of the present application is further described below in conjunction with the accompanying drawings and embodiments.

[0026] Figure 1 It is a schematic diagram of the production process flow of an embodiment of the present application;

[0027] Figure 2 It is a schematic diagram of the insulating wire structure of an embodiment of the present application. DETAILED DESCRIPTION

[0028] It should be noted that, in the absence of conflict, the embodiments and features in the embodiments of the present application may be combined with each other.

[0029] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the scope of protection of the present application. In addition, the terms "first", "second", etc. are used only for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, features defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of the invention, unless otherwise specified, "multiple" means two or more.

[0030] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood by specific circumstances.

[0031] The technical solution of the present application will be described in detail below with reference to the accompanying drawings and in combination with embodiments.

[0032] Example

[0033] This embodiment provides a three-layer wrapped insulated wire, which is wrapped with three layers of insulation by a three-station wrapping machine, and the three wrapping heads of the wrapping machine are arranged in a straight line. The wrapping head includes a turntable, a drive device and a tension control system to ensure that the wrapping tape can be evenly and tightly wrapped around the core wire.

[0034] A core wire conveying device is also provided between the three wrapping heads, and is used to feed the core wire into the wrapping heads and ensure that the core wire maintains a stable conveying speed during the wrapping process. The core wire conveying device includes a motor, a reducer, a transmission shaft and a guide device, etc.

[0035] The three-station wrapping machine also includes a tape supply device for storing and supplying the tape. The device includes a tape disk, a tension adjuster and a guide wheel to ensure that the tape can be smoothly and continuously supplied to the wrapping head.

[0036] The three-station wrapping machine also includes a control system, which includes an electrical control cabinet, a touch screen, sensors, and actuators. These components work together to achieve precise control of the wrapping process, including the adjustment of wrapping speed, tension, number of layers, and other parameters.

[0037] The following is a production process for a three-layer wrapped insulated wire. Figure 1 , the specific steps are:

[0038] First, the raw materials are prepared and tested, and high-quality single-filament tinned copper or single-filament enameled stranded wire is selected as the conductor. These materials have good conductivity, corrosion resistance and mechanical strength.

[0039] Three layers of PPS / PET tapes of different colors (the first and third layers are transparent, and the second layer is pink) are prepared. These tapes have excellent insulation properties, heat resistance, and mechanical strength.

[0040] Conduct a strict visual inspection on the incoming conductors to ensure that there are no scratches or rust. Use professional equipment to test the outer diameter (or diameter consistency), resistance, voltage resistance and other properties of the single wire to ensure that the conductor quality meets production requirements.

[0041] Then the wire is paid out and transported; the qualified conductor is placed on the pay-out rack, and the pay-out rack should be kept stable to ensure that the quality of the conductor will not be affected by vibration or shaking during transportation.

[0042] The conductor enters the power pay-off device, which is driven by a motor to allow the conductor to enter the subsequent first, second and third rubber coating areas at a stable conveying speed. The conveying speed should be adjusted according to production needs to ensure the quality of the rubber coating.

[0043] After the wire is paid off, the tape wrapping operation is carried out. The three wrapping heads of the three-station wrapping machine are arranged in a straight line. Each wrapping head includes a turntable, a drive device and a tension control system. The turntable is used to carry and rotate the tape, the drive device provides power, and the tension control system ensures that the tape maintains uniform tension during the winding process.

[0044] Tape selection and winding: In the first rubber coating area, choose transparent PPS / PET tape and choose S-direction or Z-direction winding method as needed. After entering the second rubber coating area, change to pink PPS / PET tape and change the winding direction (opposite to the first layer). In the third rubber coating area, use transparent PPS / PET tape again and choose the opposite or same winding direction as the second layer (but it should be different from the first layer to ensure the tightness and uniformity of the three insulation layers).

[0045] It should be noted that before the winding operation begins, the tape winding tension should be adjusted by the tension regulator. The tension should be determined according to factors such as the material and thickness of the tape and the diameter of the conductor to ensure that the tape can be tightly wound around the conductor while avoiding deformation or breakage of the conductor due to excessive tension.

[0046] After the lagging is completed, three heating treatments are required. The first heating treatment: preheating and initial bonding;

[0047] Purpose: To initially soften the insulating layer material and promote initial adhesion with the conductor.

[0048] Temperature and time: The preheating temperature should be set in a lower range (100℃-150℃) to avoid deformation or damage of the insulation material due to excessive temperature. The heating time should be sufficient to heat the insulation material evenly, but not too long to avoid adverse effects on subsequent processing.

[0049] Equipment: Use an oven, heating belt, or hot air circulation equipment to ensure even and controlled heating.

[0050] Second heating treatment: hot melting and tight adhesion;

[0051] Purpose: To completely melt the hot melt components in the insulation layer at a higher temperature to achieve close adhesion with the conductor.

[0052] Temperature and time: The heating temperature should be set within the range that can ensure that the hot melt component is completely melted (300-400℃), while considering the heat resistance of the insulation material and the required adhesion strength. The heating time should be sufficient to allow the hot melt component to fully flow and fill the small gap between the conductor and the insulation layer.

[0053] Equipment: Ovens, heating belts or hot air circulation equipment are also used, but the heating temperature and time need to be adjusted according to the characteristics of the insulation material.

[0054] The third heating treatment: shaping and curing;

[0055] Purpose: To rapidly cool and shape the insulating layer after hot-melt bonding, and solidify the hot-melt component to ensure the stability and durability of the insulating layer.

[0056] Temperature and time: The temperature of the cooling and shaping treatment should be gradually reduced to prevent the insulation layer material from being deformed or aged due to continuous high temperature. The cooling time should be sufficient to allow the insulation layer to completely cool and shape.

[0057] After cooling and shaping, the insulated wire products need to be inspected and unqualified products must be eliminated.

[0058] The following test items are included:

[0059] Concave-convex detection: Use professional equipment to detect the concave-convex surface of the insulated wire to ensure that the surface is flat and free of defects.

[0060] Diameter test: Use a diameter gauge to measure the diameter of the insulated wire to ensure that the diameter meets production requirements.

[0061] Spark machine inspection: The insulated wire is tested with a spark machine at high voltage to detect insulation defects or leakage. Unqualified products detected should be promptly removed and re-produced.

[0062] The insulated wire products that pass the inspection are stored and measured in meters.

[0063] Store the insulated wires that have passed the inspection on the wire storage rack for subsequent use and transportation.

[0064] During the wire storage process, a meter counter is used to record the number of meters of insulated wire produced in real time. This helps monitor production progress and product quality, and provides a basis for subsequent sales and distribution.

[0065] Reference Figure 2This embodiment also provides a wrapped three-layer insulated wire according to the production process of the above three-layer wrapped insulated wire, including a conductor, and three layers of insulation layers are wrapped around the conductor in sequence, the three layers of insulation layers are respectively a first layer of transparent PPS / PET tape, a second layer of pink PPS / PET tape and a third layer of transparent PPS / PET tape, the total thickness of the insulation layer is 18-25μm, and any two layers can withstand a safety voltage of 3KV, and the conductor is a single-filament tinned copper or a single-filament enameled twisted wire. In order to facilitate the distinction of insulated wires, the color of the first layer of insulation layer is transparent, and the thickness is 5-10 microns; the color of the second layer of insulation layer is pink; the color of the third layer of insulation layer is transparent, and any two layers of insulation layers can withstand a pulse high voltage of not less than 3KV, and the total thickness of the three layers of insulation layers is only 18-25μm.

[0066] The single wire range of this insulated wire is 0.2mm1.2mm, and the twisted wire range is 0.1mm*70.3mm*7. Non-standard products can also be made according to demand.

[0067] Application advantages: Since the covered wire can be stripped, the welded three-layer structure will not cause the risk of integration, and it has the covering strength to withstand the high-speed winding in the automatic winding machine. It adapts to the safety standards of transformers and various safety products, and realizes no obstruction barrier, miniaturization and high efficiency.

[0068] Based on the above ideal embodiments of this application, the relevant staff can make various changes and modifications without departing from the technical concept of this application through the above description. The technical scope of this application is not limited to the content in the specification, and its technical scope must be determined according to the scope of the claims.

Claims

1. A three-layer wrapped insulated wire production process, characterized in that: The following steps are involved: a. Test the appearance, outer diameter of single wire, outer diameter of twisted wire, resistance, withstand voltage and twist length of incoming materials; b. Place the incoming conductor on the pay-off rack, pay the wire with power, and the wire passes through the first, second and third rubber coating areas in sequence, and enters the lead-in, oven, testing area, wire storage rack to the take-up area; c. Carry out the rubber coating operation. The tape in the first rubber coating area is wound around the conductor in the S direction / Z direction under the action of the driving device. When it reaches the second rubber coating area, the tape is wound in the Z direction / S direction. When it enters the third rubber coating area, the tape is wound in the S direction / Z direction. The tape winding tension needs to be adjusted before the winding operation begins; d. Heat the wound product in an oven to make the hot melt layer adhere automatically; e. Conduct inspection to remove defective wires; f. Store wire and carry out meter counting process, and record the number of meters produced in real time.

2. A three-layer wrapped insulated wire production process according to claim 1, characterized in that: The tape winding tension ranges from 13 to 30 n / m, and the tape winding tension adjustment range is 0.5% to 35%.

3. A three-layer wrapped insulated wire production process according to claim 2, characterized in that: The temperature of the oven is adjusted according to the size and speed of the insulated wire, and the temperature range is 100-400°C.

4. A three-layer wrapped insulated wire production process according to claim 3, characterized in that: The inspection steps include concave-convex detection, caliper detection and spark machine detection to eliminate defective wires.

5. A wrapped three-layer insulated wire produced by the three-layer wrapped insulated wire production process according to any one of claims 1 to 4, characterized in that: The invention comprises a conductor, wherein three insulating layers are sequentially wrapped around the conductor, wherein the three insulating layers are respectively a first layer of transparent PPS / PET tape, a second layer of pink PPS / PET tape and a third layer of transparent PPS / PET tape, the total thickness of the insulating layers is 18 to 25 μm, and any two layers can withstand a safety voltage of not less than 3KV.

6. A three-layer wrapped insulated wire according to claim 5, characterized in that: The conductor is a single-filament tinned copper wire or a single-filament enameled twisted wire.

7. The three-layer wrapped insulated wire according to claim 1, characterized in that: The first insulating layer is transparent and has a thickness of 5-10 microns; the second insulating layer is pink; and the third insulating layer is transparent.

8. The three-layer wrapped insulated wire according to claim 1, characterized in that: The total thickness of the three insulating layers is only 18 to 25 μm.

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