Silica gel thread manufacturing process, silica gel thread and mold thereof

Abstract

The application discloses a silica gel wire manufacturing process and a silica gel wire and a manufacturing mold thereof. The silica gel wire manufacturing process comprises the following process steps: S1, PFA insulating layer extrusion coating; S2, bulletproof wire layer filling and stranding manufacturing; S3, PTFE sintering belt wrapping; S4, weaving anti-interference shielding layer; and S5, inner and outer silica gel layer synchronous extrusion and bulletproof wire weaving. The silica gel wire manufactured by the silica gel wire manufacturing process comprises a nickel-plated copper sensing wire, a bulletproof wire filling wire body, a PTFE sintering belt layer, an anti-interference shielding layer, an inner silica gel layer, a bulletproof wire weaving layer and an outer silica gel layer which are sequentially coated from inside to outside. The manufacturing mold of the silica gel wire manufacturing process comprises an inner cavity and an outer cavity, one end of the inner cavity is connected to an extrusion head, and the other end horizontally extends outward; and the outer cavity is arranged outside the inner cavity. The application realizes the inner and outer double-layer silica gel layer coating by adopting the double-layer silica gel synchronous extrusion, protects the internal wire and improves the heat resistance, and realizes the stable use at 250 DEG C through the material ratio of the inner and outer silica gel layers.

Description

Technical Field

[0001] This invention relates to the field of cables, and in particular to a process for manufacturing silicone wires, the silicone wires themselves, and the molds used to manufacture them. Background Technology

[0002] Silicone wire is a type of electrical wire made from silicone material, industrially known as AGR silicone rubber wire. It is manufactured using silicone material and has a suitable temperature range of -60°C to 200°C, a voltage of 300 / 500V, and a conductor of tinned copper wire and insulation of silicone rubber. Silicone wire is widely used in lighting fixtures, household appliances, electric heating appliances, instruments, motor leads, and in high-temperature environments such as electronics, lighting fixtures, and gas appliances. It is suitable for cables with a long-term permissible operating temperature below +180°C and can be used in ambient temperatures not lower than -60°C. It is used for electrical connections between mobile electrical equipment in high-temperature environments such as power generation, metallurgy, and chemical industries.

[0003] Limited by existing manufacturing processes, the maximum temperature that traditional silicone wires can withstand is 200℃. However, in actual use, there are occasions where the temperature exceeds 200℃, such as medical equipment and high-temperature food heating equipment. The heat resistance of existing silicone wires cannot meet these requirements. Therefore, it is necessary to solve the problem of silicone wires' high temperature resistance (200℃). Summary of the Invention

[0004] The technical problem to be solved by the present invention is to address the shortcomings of the prior art by providing a silicone wire manufacturing process and mold for achieving inner and outer double-layer silicone coating through synchronous extrusion of double-layer silicone, which protects the internal wire while improving heat resistance, and achieves stable use at 250°C through the material ratio of the inner and outer silicone layers.

[0005] The technical solution adopted in this invention is as follows: A process for manufacturing silicone wires, comprising the following steps: S1, PFA insulation layer extrusion coating: After at least two strands of nickel-plated copper wire are twisted together to form a wire, a PFA insulation layer is extruded and coated on the outer layer of the wire to form a nickel-plated copper sensing wire. S2, Bulletproof wire layer filling and twisting: After the two nickel-plated copper sensing wires covered with PFA insulation layer in step S1 are arranged side by side, at least two bulletproof wires are inserted into the outside and twisted together with at least two bulletproof wires to form a bulletproof wire filling wire body. S3, PTFE sintered tape wrapping: The stranded wire body in step S2 is wrapped with a PTFE sintered tape layer to fix the stranded wire body; S4. Braided anti-interference shielding layer: In step S3, an anti-interference shielding layer is braided onto the surface of the PTFE sintered tape wrapped around the stranded wire. S5. Synchronous extrusion of inner and outer silicone layers and weaving of bulletproof wire: In step S4, silicone is extruded synchronously through a mold to form an inner silicone layer and an outer silicone layer on the surface of the anti-interference shielding layer. The inner silicone layer covers the surface of the anti-interference shielding layer, and a bulletproof wire braided layer is woven on the inner silicone layer during the synchronous extrusion of the inner and outer silicone layers. The outer silicone layer covers the surface of the bulletproof wire braided layer.

[0006] Preferably, in S1, the nickel plating layer on the surface of the nickel-plated copper wire is greater than 0.3 μm; the diameter of the nickel-plated copper wire is 0.08 mm; the at least two strands of nickel-plated copper wire include 19 strands of nickel-plated copper wire, and the 19 strands of nickel-plated copper wire are twisted together to form a wire.

[0007] Preferably, in step S1, the PFA insulation layer is coated onto the surface of the conductor by high-temperature extrusion; the temperature range of the high-temperature extrusion is 330°C to 390°C, and by placing the extrusion tube in a vacuum environment, the extrusion air bubbles inside the PFA insulation layer are reduced and the adhesion to the conductor surface is improved.

[0008] Preferably, the bulletproof wire in steps S2 and S5 is 1500D water-resistant bulletproof wire with a tensile strength greater than 20kg.

[0009] Preferably, in step S4, the anti-interference shielding layer has a surface coverage of more than 95% on the stranded wire to reduce external magnetic field interference.

[0010] Preferably, in step S5, the weight ratio of the inner and outer silicone layers is: 94% mSiO2·nH2O, 4% heat resistant agent and color masterbatch, and 2% A and B platinum vulcanizing agents. The materials for the inner and outer silicone layers are prepared through a mixing process, with a mixing time of 15 to 20 minutes. During the mixing process, firstly, 47% of mSiO2·nH2O and 0.7% of A platinum vulcanizing agent are mixed evenly to form A-type adhesive; secondly, 47% of mSiO2·nH2O and 1.3% of B platinum vulcanizing agent are mixed evenly to form... B-type glue; then A-type glue and B-type glue are mixed evenly; then 4% heat resistant agent and color masterbatch are added to the mixed AB-type glue, and the mixture is sliced ​​and fed into a silicone extruder to be extruded into a mold. After being extruded through the mold, it is simultaneously extruded and coated on the surface of the anti-interference shielding layer; the extrusion speed is 10m / min, and the preheating temperature before extrusion is 200℃; the surface of the outer silicone layer is treated with gamma rays to reduce the surface viscosity and friction of the outer silicone layer; in step S5, the bulletproof wire braided layer is woven from 8*1 / 100D water-resistant bulletproof wire with a density of 10 mesh.

[0011] Preferably, the die is connected to the extrusion head of the extruder and includes an inner cavity and an outer cavity. One end of the inner cavity is connected to the extrusion head, and the other end extends horizontally outward. A wire hole is provided in the middle of the inner cavity. The wire hole passes through the inner cavity and the extrusion head, and the wire passes through the wire hole and is pulled straight out of the inner cavity from the direction of the extrusion head. The outer cavity is fitted outside the inner cavity, and one end is connected to the extrusion head, while the other end extends horizontally outward. A silicone flow channel is formed between the outer cavity and the inner cavity. The silicone flow channel includes a first flow channel and a second flow channel connected sequentially from the direction of the extrusion head. The first flow channel extends horizontally outward and communicates with the extrusion head to horizontally discharge fluid silicone. The second flow channel communicates with the first flow channel and extends outward and upward along the radial direction of the wire hole to both sides, forming a protrusion, and forming an opening on both sides with the wire hole. The winding space is provided; the first flow channel is provided with a first injection hole, which is opened on the wall of the inner cavity and passes through the first flow channel and the wire hole; the first injection hole includes at least two, which are spaced apart along the circumferential direction on the wall of the inner cavity, so as to inject liquid silicone into the wire hole and pull outward to the surface of the anti-interference shielding layer of the wire, forming an inner silicone layer; after the inner silicone layer is formed on the surface of the wire, when it moves to the winding space, the surface is braided with bulletproof wire to form a bulletproof wire braided layer; the outer end of the second flow channel extends radially toward the wire hole and forms a second injection hole near the wire hole. After the liquid silicone is injected at the first injection hole, the remaining silicone flows into the second flow channel and is injected again through the second injection hole onto the surface of the braided bulletproof wire braided layer to form an outer silicone layer.

[0012] Preferably, a flow-blocking ring is provided inside the wire hole; the flow-blocking ring is connected to the inner wall of the inner cavity and is located on the side of the first glue injection hole near the extrusion head; the inner wall of the flow-blocking ring is close to the surface of the anti-interference shielding layer of the wire body inside the wire hole, so as to radially limit the wire body when it is pulled out and block the backflow when the glue is injected into the wire hole from the first glue injection hole.

[0013] Preferably, the first flow channel is provided with a first guide ring and a second guide ring. The first guide ring is disposed on the inner wall of the outer cavity, located on the side of the first injection hole near the extruder head, and a gap is left between it and the outer wall of the inner cavity so as to guide the fluid silicone from the extruder head toward the first injection hole. The second guide ring is disposed on the outer wall of the inner cavity, located on the side of the first injection hole away from the extruder head, and a gap is left between it and the inner wall of the outer cavity so as to block the fluid silicone on the inner side so as to allow it to enter the first injection hole, and to reserve flow space on the outer side for entering the second flow channel.

[0014] A silicone wire manufacturing process includes, from the inside out, a nickel-plated copper sensing wire, a bulletproof wire filling wire body, a PTFE sintered tape layer, an anti-interference shielding layer, an inner silicone layer, a bulletproof wire braided layer, and an outer silicone layer.

[0015] A molding die for manufacturing silicone wire includes an inner cavity and an outer cavity. One end of the inner cavity is connected to an extrusion head, and the other end extends horizontally outward. A wire hole is provided in the middle of the inner cavity. The wire hole passes through the inner cavity and the extrusion head, and the wire passes through the wire hole and is pulled straight out of the inner cavity from the direction of the extrusion head. The outer cavity is fitted outside the inner cavity, with one end connected to the extrusion head and the other end extending horizontally outward. A silicone flow channel is formed between the outer cavity and the inner cavity. The silicone flow channel includes a first flow channel and a second flow channel connected sequentially from the direction of the extrusion head. The first flow channel extends horizontally outward and communicates with the extrusion head to horizontally discharge the fluid. Silicone; the second flow channel communicates with the first flow channel and extends outward and upward along the radial direction of the wire hole to form a convex body, forming a winding space with open front and rear sides between it and the wire hole; the first flow channel is provided with a first injection hole, which is opened on the wall of the inner cavity and passes through the first flow channel and the wire hole; the first injection hole includes at least two, and at least two first injection holes are spaced apart along the circumferential direction on the wall of the inner cavity so as to inject liquid silicone into the wire hole and pull outward to the surface of the anti-interference shielding layer of the wire body, forming an inner silicone layer; after the inner silicone layer is formed on the surface of the wire body, it moves to the winding. In the space, bulletproof wire is woven on the surface to form a bulletproof wire braided layer; the outer end of the second flow channel extends radially toward the wire hole, and a second injection hole is formed near the wire hole. After the fluid silicone is injected at the first injection hole, the remaining silicone flows into the second flow channel and is injected again through the second injection hole onto the surface of the woven bulletproof wire braided layer to form an outer silicone layer; a flow-blocking and limiting ring is provided inside the wire hole; the flow-blocking and limiting ring is connected to the inner wall of the inner cavity and is located on the side of the first injection hole near the extrusion head; the inner wall of the flow-blocking and limiting ring is close to the anti-interference shielding layer surface of the wire body inside the wire hole so that the wire body can be pulled out in diameter The flow channel is designed to limit and prevent backflow when the first injection hole injects silicone into the wire hole. A first guide ring and a second guide ring are provided within the first flow channel. The first guide ring is located on the inner wall of the outer cavity, near the extruder head of the first injection hole, and has a gap with the outer wall of the inner cavity to guide the fluid silicone from the extruder head towards the first injection hole. The second guide ring is located on the outer wall of the inner cavity, away from the extruder head of the first injection hole, and has a gap with the inner wall of the outer cavity to block the fluid silicone from entering the first injection hole on the inner side, while reserving flow space on the outer side for entry into the second flow channel.

[0016] The beneficial effects of this invention are as follows: This invention addresses the shortcomings and deficiencies of existing technologies by independently developing and designing a silicone wire manufacturing process that utilizes simultaneous extrusion of double-layer silicone to achieve inner and outer double-layer silicone coating. This process protects the internal wire while improving heat resistance. The material ratio of the inner and outer silicone layers ensures stable operation at 250℃. The invention also includes the silicone wire and its manufacturing mold. Compared to traditional silicone wires, this invention achieves simultaneous extrusion and coating of the inner and outer silicone layers through the manufacturing mold, effectively improving the efficiency of silicone layer manufacturing while simultaneously achieving double silicone layer coating. During the simultaneous extrusion of the double silicone layers, the open structure at the front and rear of the mold's protrusions allows the braided bulletproof wire layer to be woven over the continuously extruded inner silicone layer before simultaneously completing the outer silicone layer. The double silicone layers protect the internal wire, improving heat resistance, while the centrally braided bulletproof wire layer stabilizes the flexible shape and structure of the inner and outer silicone layers, enhancing the overall tensile strength of the double silicone layers.

[0017] Specifically, the silicone wire manufactured in this invention comprises eight layers from the inside out: a nickel-copper plated sensing wire, a bulletproof wire filler wire, a PTFE sintered tape layer, an anti-interference shielding layer, an inner silicone layer, a bulletproof wire braided layer, and an outer silicone layer. The nickel-copper plated sensing wire is a wire structure formed by twisting at least two strands of nickel-copper plated wire. The surface of the nickel-copper plated sensing wire is covered with a PFA insulation layer, which is formed by high-temperature extrusion of PFA material onto the surface of the nickel-copper plated sensing wire. The bulletproof wire filler wire is formed by filling the outside of two parallel nickel-copper plated sensing wires. The system comprises at least two bulletproof wires twisted together to form a filament; a PTFE sintered tape layer is formed by wrapping a flexible PTFE tape around the surface of the bulletproof wire filling filament; an anti-interference shielding layer is formed by weaving anti-interference material onto the surface of the PTFE sintered tape layer; an inner silicone layer and an outer silicone layer are extruded at high temperature using a synchronous extrusion process through a mold; the inner silicone layer is extruded and covers the anti-interference shielding layer, and its surface is woven with a bulletproof wire braided layer; the outer silicone layer is synchronously extruded and covers the surface of the bulletproof wire braided layer. The invention comprises the following components: 1. The sensing wire is made of nickel-plated copper, which is resistant to high temperatures; 2. The wire insulation layer is extruded with PFA (polyvinyl fluoride copolymer), which has excellent chemical resistance, corrosion resistance, high temperature stability, oxidation resistance, and low viscosity; 3. Bulletproof wire is used to fill the wire, protecting it from tensile and bending stresses; 4. PTFE sintered tape is used to fix the sensing wire; 5. Nickel-plated copper braided shielding resists magnetic field interference and meets the 250℃ requirement; 6. Food-grade silicone rubber is used for vulcanization, with a certain proportion of heat-resistant agent added, which meets the 250℃ operating conditions; 7. The outer silicone layer is extruded in two stages, with a fine bulletproof mesh woven in the middle to ensure no deformation under high temperature conditions; 8. The surface of the silicone wire is treated with gamma rays for surface activation (photomodification process), reducing the surface viscosity and friction of the outer silicone layer. In terms of manufacturing process, this invention uses a food-grade silicone + heat-resistant agent vulcanization process, achieving an increased heat resistance temperature through a mass ratio of 94% mSiO2·nH2O, 4% heat-resistant agent and color masterbatch, and 2% A and B platinum vulcanizing agents.

[0018] In addition, this invention addresses the manufacturing process requirements of coating the inner and outer silicone layers of the production line by designing a manufacturing mold. The manufacturing mold is connected to the extrusion head of the extruder and includes an inner cavity and an outer cavity with inner and outer shells. A silicone flow channel is formed between the inner cavity and the outer cavity. The silicone flow channel includes a first flow channel and a second flow channel that are interconnected and move to the left along the direction of the extrusion head. A wire hole that runs through the left and right is provided in the middle of the inner cavity. The production line coated with the anti-interference shielding layer passes through the extrusion head and the wire hole from left to right and moves linearly to the left under the action of an external mechanism. When the liner moves to the first injection hole in the inner cavity, the fluid silicone in the first channel is introduced into the liner hole through the first injection hole and covers the surface of the anti-interference shielding layer of the moving liner, forming an inner silicone layer. As the liner covered with the inner silicone layer continues to move straight to the left, it passes the protrusion formed by the second channel. At the open structures on the front and back sides of the protrusion, bulletproof wire is woven, so that the surface of the inner silicone layer is covered with a bulletproof wire woven layer. At the protrusion, in order to accelerate the surface solidification of the inner silicone layer during the weaving of the bulletproof wire, an air-cooling mechanism can be set on the front and back open sides of the protrusion to cool the inner silicone layer covering the surface of the anti-interference shielding layer. After the bulletproof wire woven layer is formed, the liner continues to move straight to the left to the second injection hole. The fluid silicone in the second channel is injected into the liner hole through the second injection hole and covers the surface of the bulletproof wire woven layer of the moving liner. In addition, the present invention provides a flow-limiting ring inside the line hole. By placing the flow-limiting ring on the right side of the first injection hole near the extruder head and connecting it to the inner wall of the inner cavity, it ensures radial guidance and limitation of the line body during the pulling process, and also blocks the silicone from flowing into the line hole when the first injection hole injects silicone, preventing the silicone from flowing into the right side of the line hole during injection. Simultaneously, the present invention provides a first guide ring and a second guide ring within the first flow channel. The first guide ring is fixed to the inner wall of the outer cavity, with a gap between it and the outer wall of the inner cavity, and is located on the right side of the first injection hole. When the silicone in the extruder head flows to the right within the first flow channel, it passes through the gap between the first guide ring and the outer wall of the inner cavity, and is guided downwards by the first guide ring for better injection into the first injection hole. The second guide ring is positioned to the left of the first injection hole and fixed to the outer wall of the inner cavity. A gap space is formed between the second guide ring and the inner wall of the outer cavity. The second guide ring obstructs the flow of silicone in the first channel, allowing the silicone to flow better into the first injection hole. Simultaneously, the remaining silicone flows into the second channel through the gap space between the second guide ring and the inner wall of the outer cavity, and gradually flows to the right along the convex shape to the second injection hole. Finally, it is discharged through the second injection hole and covers the surface of the line body. Furthermore, to ensure smooth flow of silicone in the first and second channels, a heating device can be installed outside the outer cavity, such as using a hot water circulation pipe for heat exchange, to ensure the temperature stability of the outer cavity and prevent silicone blockage due to temperature drop. Attached Figure Description

[0019] Figure 1This is a schematic diagram illustrating the process steps of the present invention.

[0020] Figure 2 This is a cross-sectional view of the silicone wire of the present invention.

[0021] Figure 3 This is a top view of the silicone wire body of the present invention.

[0022] Figure 4 A cross-sectional view of the mold used to manufacture this invention. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0024] It should be noted that all directional indications in the embodiments of the present invention, such as up, down, left, right, front, back, etc., are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0025] In this invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0026] like Figure 1 As shown, this invention proposes a process for manufacturing silicone wires, comprising the following steps: S1, PFA insulation layer extrusion coating: After at least two strands of nickel-plated copper wires are twisted together to form a wire, a PFA insulation layer is extruded and coated on the outer layer of the wire to form a nickel-plated copper sensing wire. S2, Bulletproof wire layer filling and twisting: After the two nickel-plated copper sensing wires covered with PFA insulation layer in step S1 are arranged side by side, at least two bulletproof wires are inserted into the outside and twisted together with at least two bulletproof wires to form a bulletproof wire filling wire body. S3, PTFE sintered tape wrapping: The stranded wire body in step S2 is wrapped with a PTFE sintered tape layer to fix the stranded wire body; S4. Braided anti-interference shielding layer: In step S3, an anti-interference shielding layer is braided onto the surface of the PTFE sintered tape wrapped around the stranded wire. S5. Synchronous extrusion of inner and outer silicone layers and weaving of bulletproof wire: In step S4, silicone is extruded synchronously through a mold to form an inner silicone layer and an outer silicone layer on the surface of the anti-interference shielding layer. The inner silicone layer covers the surface of the anti-interference shielding layer, and a bulletproof wire braided layer is woven on the inner silicone layer during the synchronous extrusion of the inner and outer silicone layers. The outer silicone layer covers the surface of the bulletproof wire braided layer.

[0027] In step S1, the nickel plating layer on the surface of the nickel-plated copper wire is greater than 0.3 μm; the diameter of the nickel-plated copper wire is 0.08 mm; the at least two strands of nickel-plated copper wire include 19 strands of nickel-plated copper wire, which are twisted together to form a wire.

[0028] In step S1, the PFA insulation layer is coated onto the surface of the conductor in step S1 by high-temperature extrusion; the temperature range of the high-temperature extrusion is 330°C to 390°C, and the extrusion tube is placed in a vacuum environment to reduce extrusion bubbles inside the PFA insulation layer and improve adhesion to the conductor surface.

[0029] In steps S2 and S5, the bulletproof wire is 1500D water-resistant bulletproof wire with a tensile strength greater than 20kg.

[0030] In step S4, the anti-interference shielding layer has a surface coverage of more than 95% on the stranded wire to reduce external magnetic field interference.

[0031] The weight ratio of the inner and outer silicone layers in step S5 is: 94% mSiO2·nH2O, 4% heat resistant agent and color masterbatch, and 2% A and B platinum vulcanizing agents. The materials of the inner and outer silicone layers are made by a mixing process, with a mixing time of 15 to 20 minutes. During the mixing process, 47% mSiO2·nH2O and 0.7% A platinum vulcanizing agent are first mixed evenly to form A glue; then 47% mSiO2·nH2O and 1.3% B platinum vulcanizing agent are mixed evenly to form B glue. Next, A and B adhesives are mixed evenly. Then, 4% heat resistant agent and color masterbatch are added to the mixed AB adhesives, and the mixture is slicing and extruded into a silicone extruder. The extrusion is then simultaneously extruded through the mold and coated onto the surface of the anti-interference shielding layer. The extrusion speed is 10 m / min, and the preheating temperature before extrusion is 200°C. The surface of the outer silicone layer is treated with gamma rays to reduce the surface viscosity and friction of the outer silicone layer. In step S5, the bulletproof wire braided layer is woven from 8*1 / 100D water-resistant bulletproof wire with a density of 10 mesh.

[0032] like Figure 4As shown in the figure, as an embodiment of the present invention, the die is connected to the extrusion head 01 of the extruder and includes an inner cavity 02 and an outer cavity 03. One end of the inner cavity 02 is connected to the extrusion head 01, and the other end extends horizontally outward. A wire hole A is provided in the middle of the inner cavity 02. The wire hole A passes through the inner cavity 02 and the extrusion head 01, and the wire passes through the wire hole A and is pulled straight out from the direction of the extrusion head 01 toward the inner cavity 02. The outer cavity 03 is sleeved outside the inner cavity 02, and one end is connected to the extrusion head 01, and the other end extends horizontally outward. A silicone flow channel is formed between the outer cavity 03 and the inner cavity 02. The silicone flow channel includes a first flow channel B and a second flow channel D connected sequentially from the direction of the extrusion head 01. The first flow channel B extends horizontally outward and communicates with the extrusion head 01 to horizontally discharge fluid silicone. The second flow channel D communicates with the first flow channel B and extends outward and upward along the radial direction of the wire hole A to form a protrusion. The first flow channel B is provided with a first injection hole C, which is opened on the wall of the inner cavity 02 and passes through the first flow channel B and the wire hole A. The first injection hole C includes at least two holes, which are spaced apart along the circumferential direction on the wall of the inner cavity 02 so as to inject liquid silicone into the surface of the anti-interference shielding layer 5 of the wire pulled out of the wire hole A to form an inner silicone layer 6. When the wire moves to the winding space F after the inner silicone layer 6 is formed on the surface of the wire, bulletproof wire is woven on the surface to form a bulletproof wire braided layer 7. The outer end of the second flow channel D extends radially toward the wire hole A and forms a second injection hole E near the wire hole A. After the liquid silicone is injected at the first injection hole C, the remaining silicone flows into the second flow channel D and is injected again through the second injection hole C onto the surface of the braided bulletproof wire braided layer 7 to form an outer silicone layer 8.

[0033] A flow-limiting ring 04 is provided inside the wire hole A; the flow-limiting ring 04 is connected to the inner wall of the inner cavity 02 and is located on the side of the first glue injection hole C near the extrusion head 01; the inner wall of the flow-limiting ring 04 is close to the surface of the anti-interference shielding layer 5 of the wire body inside the wire hole A, so as to limit the radial movement of the wire body when it is pulled out, and to prevent backflow when the glue is injected from the first glue injection hole C into the wire hole A.

[0034] The first flow channel B is provided with a first guide ring 05 and a second guide ring 06. The first guide ring 05 is disposed on the inner wall of the outer cavity 03, located on the side of the first injection hole C near the extruder head 01, and has a gap between it and the outer wall of the inner cavity 02 so as to guide the fluid silicone from the extruder head 01 toward the first injection hole C. The second guide ring 06 is disposed on the outer wall of the inner cavity 02, located on the side of the first injection hole C away from the extruder head 01, and has a gap between it and the inner wall of the outer cavity 03 so as to block the fluid silicone from entering the first injection hole C on the inner side, and reserve flow space on the outer side for entering the second flow channel D.

[0035] like Figures 2 to 3 As shown in the figure, as an embodiment of the present invention, a silicone wire manufactured according to a process of the present invention includes, from the inside out, a nickel-plated copper sensing wire 1, a bulletproof wire filling body 3, a PTFE sintered tape layer 4, an anti-interference shielding layer 5, an inner silicone layer 6, a bulletproof wire braided layer 7, and an outer silicone layer 8, wherein the nickel-plated copper sensing wire 1 is a wire structure formed by twisting at least two strands of nickel-plated copper wire; the surface of the nickel-plated copper sensing wire 1 is covered with a PFA insulation layer 2, which is formed by high-temperature extrusion of PFA material onto the surface of the nickel-plated copper sensing wire 1; the bulletproof wire filling body 3 is composed of two parallel The nickel-plated copper sensing wire 1 is filled with at least two bulletproof wires and twisted together to form a wire body; the PTFE sintered tape layer 4 is formed by wrapping a flexible PTFE tape around the surface of the bulletproof wire-filled wire body 3; the anti-interference shielding layer 5 is formed by weaving anti-interference material onto the surface of the PTFE sintered tape layer 4; the inner silicone layer 6 and the outer silicone layer 8 are extruded at high temperature using a synchronous extrusion process through a mold; the inner silicone layer 6 is extruded and covers the anti-interference shielding layer 5, and its surface is woven with a bulletproof wire braided layer 7; the outer silicone layer 8 is synchronously extruded and covers the surface of the bulletproof wire braided layer 7.

[0036] like Figure 4As shown in the figure, as an embodiment of the present invention, a mold for manufacturing silicone wire includes an inner cavity 02 and an outer cavity 03. One end of the inner cavity 02 is connected to an extrusion head 01, and the other end extends horizontally outward. A wire hole A is provided in the middle of the inner cavity 02. The wire hole A passes through the inner cavity 02 and the extrusion head 01, and the wire passes through the wire hole A and is pulled straight out from the direction of the extrusion head 01 toward the inner cavity 02. The outer cavity 03 is sleeved outside the inner cavity 02, and one end is connected to the extrusion head 01, and the other end extends horizontally outward. A silicone flow channel is formed between the outer cavity 03 and the inner cavity 02. The silicone flow channel includes a first flow channel B and a second flow channel D connected sequentially from the direction of the extrusion head 01. The first flow channel B extends horizontally... The second flow channel D extends outward and communicates with the extrusion head 01 to horizontally discharge fluid silicone; the second flow channel D communicates with the first flow channel B and extends outward and upward along the radial direction of the wire hole A to form a convex body, forming a winding space F with open front and rear sides between it and the wire hole A; the first flow channel B is provided with a first injection hole C, which is opened on the wall of the inner cavity 02 and passes through the first flow channel B and the wire hole A; the first injection hole C includes at least two, and at least two first injection holes C are opened at intervals along the circumferential direction on the wall of the inner cavity 02 to inject fluid silicone into the surface of the anti-interference shielding layer 5 of the wire body pulled outward from the wire hole A, forming an inner silicone layer 6; the inner layer is formed on the surface of the wire body. When the silicone layer 6 moves to the winding space F, bulletproof wires are woven on its surface to form a bulletproof wire braided layer 7. The outer end of the second flow channel D extends radially toward the wire hole A, and a second injection hole E is formed near the wire hole A. After the fluid silicone is injected at the first injection hole C, the remaining silicone flows into the second flow channel D and is injected again through the second injection hole C onto the surface of the braided bulletproof wire braided layer 7 to form an outer silicone layer 8. A flow-limiting ring 04 is provided inside the wire hole A. The flow-limiting ring 04 is connected to the inner wall of the inner cavity 02 and is located on the side of the first injection hole C near the extruder head 01. The inner wall of the flow-limiting ring 04 is close to the surface of the anti-interference shielding layer 5 of the wire body inside the wire hole A so that when the wire body is pulled out... Radial limiting and blocking backflow when the first injection hole C injects glue into the wire hole A; the first flow channel B is provided with a first guide ring 05 and a second guide ring 06, wherein the first guide ring 05 is disposed on the inner wall of the outer cavity 03, located on the side of the first injection hole C near the extrusion head 01, and a gap is left between it and the outer wall of the inner cavity 02 so as to guide the fluid silicone out of the extrusion head 01 towards the first injection hole C; the second guide ring (06) is disposed on the outer wall of the inner cavity 02, located on the side of the first injection hole C away from the extrusion head 01, and a gap is left between it and the inner wall of the outer cavity 03 so as to block the fluid silicone on the inner side so as to allow it to enter the first injection hole C, and reserve flow space on the outer side for entering the second flow channel D.

[0037] Furthermore, this invention designs a silicone wire manufacturing process that achieves simultaneous extrusion of two layers of silicone to cover both the inner and outer layers, protecting the internal wire while improving heat resistance. The process, along with the silicone wire and its manufacturing mold, utilizes the material ratio of the inner and outer silicone layers to achieve stable operation at 250℃. Compared to traditional silicone wires, this invention achieves simultaneous extrusion and coating of the inner and outer silicone layers through the manufacturing mold, effectively improving the efficiency of silicone layer manufacturing while achieving dual silicone layer coating. Simultaneously, the open structure at the front and rear of the mold's protrusions allows the braided bulletproof wire layer to be woven over the continuously extruded inner silicone layer before the outer silicone layer is simultaneously completed. The dual silicone layers protect the internal wire, improving heat resistance, while the centrally braided bulletproof wire layer stabilizes the flexible shape and structure of the inner and outer silicone layers, enhancing the overall tensile strength of the dual silicone layers. Specifically, the silicone wire manufactured in this invention comprises eight layers from the inside out: a nickel-copper plated sensing wire, a bulletproof wire filler wire, a PTFE sintered tape layer, an anti-interference shielding layer, an inner silicone layer, a bulletproof wire braided layer, and an outer silicone layer. The nickel-copper plated sensing wire is a wire structure formed by twisting at least two strands of nickel-copper plated wire. The surface of the nickel-copper plated sensing wire is covered with a PFA insulation layer, which is formed by high-temperature extrusion of PFA material onto the surface of the nickel-copper plated sensing wire. The bulletproof wire filler wire is formed by filling the outside of two parallel nickel-copper plated sensing wires. The system comprises at least two bulletproof wires twisted together to form a filament; a PTFE sintered tape layer is formed by wrapping a flexible PTFE tape around the surface of the bulletproof wire filling filament; an anti-interference shielding layer is formed by weaving anti-interference material onto the surface of the PTFE sintered tape layer; an inner silicone layer and an outer silicone layer are extruded at high temperature using a synchronous extrusion process through a mold; the inner silicone layer is extruded and covers the anti-interference shielding layer, and its surface is woven with a bulletproof wire braided layer; the outer silicone layer is synchronously extruded and covers the surface of the bulletproof wire braided layer. The invention comprises the following components: 1. The sensing wire is made of nickel-plated copper, which is resistant to high temperatures; 2. The wire insulation layer is extruded with PFA (polyvinyl fluoride copolymer), which has excellent chemical resistance, corrosion resistance, high temperature stability, oxidation resistance, and low viscosity; 3. Bulletproof wire is used to fill the wire, protecting it from tensile and bending stresses; 4. PTFE sintered tape is used to fix the sensing wire; 5. Nickel-plated copper braided shielding resists magnetic field interference and meets the 250℃ requirement; 6. Food-grade silicone rubber is used for vulcanization, with a certain proportion of heat-resistant agent added, which meets the 250℃ operating conditions; 7. The outer silicone layer is extruded in two stages, with a fine bulletproof mesh woven in the middle to ensure no deformation under high temperature conditions; 8. The surface of the silicone wire is treated with gamma rays for surface activation (photomodification process), reducing the surface viscosity and friction of the outer silicone layer. In terms of manufacturing process, this invention uses a food-grade silicone + heat-resistant agent vulcanization process, achieving an increased heat resistance temperature through a mass ratio of 94% mSiO2·nH2O, 4% heat-resistant agent and color masterbatch, and 2% A and B platinum vulcanizing agents.In addition, this invention addresses the manufacturing process requirements of coating the inner and outer silicone layers of the production line by designing a manufacturing mold. The manufacturing mold is connected to the extrusion head of the extruder and includes an inner cavity and an outer cavity with inner and outer shells. A silicone flow channel is formed between the inner cavity and the outer cavity. The silicone flow channel includes a first flow channel and a second flow channel that are interconnected and move to the left along the direction of the extrusion head. A wire hole that runs through the left and right is provided in the middle of the inner cavity. The production line coated with the anti-interference shielding layer passes through the extrusion head and the wire hole from left to right and moves linearly to the left under the action of an external mechanism. When the liner moves to the first injection hole in the inner cavity, the fluid silicone in the first channel is introduced into the liner hole through the first injection hole and covers the surface of the anti-interference shielding layer of the moving liner, forming an inner silicone layer. As the liner covered with the inner silicone layer continues to move straight to the left, it passes the protrusion formed by the second channel. At the open structures on the front and back sides of the protrusion, bulletproof wire is woven, so that the surface of the inner silicone layer is covered with a bulletproof wire woven layer. At the protrusion, in order to accelerate the surface solidification of the inner silicone layer during the weaving of the bulletproof wire, an air-cooling mechanism can be set on the front and back open sides of the protrusion to cool the inner silicone layer covering the surface of the anti-interference shielding layer. After the bulletproof wire woven layer is formed, the liner continues to move straight to the left to the second injection hole. The fluid silicone in the second channel is injected into the liner hole through the second injection hole and covers the surface of the bulletproof wire woven layer of the moving liner. In addition, the present invention provides a flow-limiting ring inside the line hole. By placing the flow-limiting ring on the right side of the first injection hole near the extruder head and connecting it to the inner wall of the inner cavity, it ensures radial guidance and limitation of the line body during the pulling process, and also blocks the silicone from flowing into the line hole when the first injection hole injects silicone, preventing the silicone from flowing into the right side of the line hole during injection. Simultaneously, the present invention provides a first guide ring and a second guide ring within the first flow channel. The first guide ring is fixed to the inner wall of the outer cavity, with a gap between it and the outer wall of the inner cavity, and is located on the right side of the first injection hole. When the silicone in the extruder head flows to the right within the first flow channel, it passes through the gap between the first guide ring and the outer wall of the inner cavity, and is guided downwards by the first guide ring for better injection into the first injection hole. The second guide ring is positioned to the left of the first injection hole and fixed to the outer wall of the inner cavity. A gap space is formed between the second guide ring and the inner wall of the outer cavity. The second guide ring obstructs the flow of silicone in the first channel, allowing the silicone to flow better into the first injection hole. Simultaneously, the remaining silicone flows into the second channel through the gap space between the second guide ring and the inner wall of the outer cavity, and gradually flows to the right along the convex shape to the second injection hole. Finally, it is discharged through the second injection hole and covers the surface of the line body. Furthermore, to ensure smooth flow of silicone in the first and second channels, a heating device can be installed outside the outer cavity, such as using a hot water circulation pipe for heat exchange, to ensure the temperature stability of the outer cavity and prevent silicone blockage due to temperature drop.

[0038] Specifically, the wire gauge and material standards of this invention are as follows: Conductor section Material: Nickel plated copper; Size (wire gauge): 28AWG; Construction (structure): 19 / 0.08MM; Outer diameter: 0.40mm.

[0039] Insulation section Material: PFA; Average Thickness: 0.17mm; Minimum Thickness: 0.14mm; Outer diameter: 0.74±0.05mm; Color: Black, Red.

[0040] Strands (twisted) Pitch: 12.7±2mm; Filler: 1500D Kevlar * 4 PCS; Tape: PTFE wrap, Overlap Rate 50%; Outer diameter: 1.70mm.

[0041] Shield section Material: Nickel plated copper (16*5 / 0.08); Type: Braid; Coverage rate: 85%-95%.

[0042] Jacket (shelter) Material: Medical Silicone (R406 / 70); Braid kevlar (braided aramid): 8 Spindles braid; Average Thickness: 0.85mm; Minimum Thickness: 0.68mm Outer diameter: 3.66±0.25mm; Color: Black.

[0043] The specific characteristic parameters of the wire of this invention are as follows: Conductor Resistance (@20°C): 0.25Ω / m, Max. Insulation Resistance (@20°C): 100 MΩ / km, Min. Temperature Rating: 250℃; Stretching resistance (tensile strength): >20 kgf.1 minutes; Bending, Load 227g, ±90°R=10mm, 30 Cycels / min: >10000 Cycles.

[0044] The embodiments of this invention are merely illustrative of specific implementation methods and are not intended to limit the scope of protection. Those skilled in the art can make modifications based on these embodiments; therefore, all equivalent changes or modifications made in accordance with the scope of this invention's patent claims fall within the scope of this invention's patent claims.

Claims

1. A mold for making silicone wire, connected to the extrusion head (01) of an extruder, characterized in that: Includes an inner cavity (02) and an outer cavity (03), wherein, One end of the inner cavity (02) is connected to the extrusion head (01), and the other end extends horizontally outward. A wire hole (A) is provided in the middle of the inner cavity (02). The wire hole (A) passes through the inner cavity (02) and the extrusion head (01). The wire passes through the wire hole (A) and is pulled straight out from the direction of the extrusion head (01) into the inner cavity (02). The outer cavity (03) is fitted outside the inner cavity (02), and one end is connected to the extrusion head (01), while the other end extends horizontally outward, forming a silicone flow channel between the outer cavity (03) and the inner cavity (02); The silicone flow channel includes a first flow channel (B) and a second flow channel (D) connected sequentially from the extruder (01) outward; the first flow channel (B) extends horizontally outward and communicates with the extruder (01) so as to horizontally discharge fluid silicone. The second flow channel (D) is connected to the first flow channel (B) and extends outward and upward along the radial direction of the wire hole (A) to form a convex body, and forms a winding space (F) with the wire hole (A) open on both the front and rear sides. The first flow channel (B) is provided with a first injection hole (C), which is opened on the wall of the inner cavity (02) and passes through the first flow channel (B) and the wire hole (A); the first injection hole (C) includes at least two, and at least two first injection holes (C) are opened at intervals along the circumferential direction on the wall of the inner cavity (02) so as to inject liquid silicone into the surface of the anti-interference shielding layer (5) of the wire pulled out from the wire hole (A) to form an inner silicone layer (6). When the inner silicone layer (6) is formed on the surface of the wire and it moves to the winding space (F), the surface is braided with bulletproof wire to form a bulletproof wire braided layer (7). The outer end of the second flow channel (D) extends radially toward the wire hole (A) and forms a second injection hole (E) near the wire hole (A). After the fluid silicone is injected at the first injection hole (C), the remaining silicone flows into the second flow channel (D) and is injected again through the second injection hole (C) onto the surface of the braided bulletproof wire braided layer (7) to form an outer silicone layer (8).

2. The mold for making silicone wire according to claim 1, characterized in that: The wire hole (A) is provided with a flow-blocking ring (04); the flow-blocking ring (04) is connected to the inner wall of the inner cavity (02) and is located on the side of the first glue injection hole (C) near the extruder (01); the inner wall of the flow-blocking ring (04) is close to the surface of the anti-interference shielding layer (5) of the wire body in the wire hole (A) so as to radially limit the wire body when it is pulled out and block the backflow when the first glue injection hole (C) injects glue into the wire hole (A); The first flow channel (B) is provided with a first guide ring (05) and a second guide ring (06). The first guide ring (05) is disposed on the inner wall of the outer cavity (03), located on the side of the first injection hole (C) close to the extruder (01), and a gap is left between it and the outer wall of the inner cavity (02) so as to guide the fluid silicone from the extruder (01) toward the first injection hole (C). The second guide ring (06) is disposed on the outer wall of the inner cavity (02), located on the side of the first injection hole (C) away from the extruder (01), and a gap is left between it and the inner wall of the outer cavity (03) so as to block the fluid silicone on the inner side so as to allow it to enter the first injection hole (C), and reserve flow space on the outer side for entering the second flow channel (D).

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