A formula for insulation layer of communication cable and production process of communication cable

Abstract

The present invention relates to a formula of an insulating layer of a communication cable in the production field of communication cables and a production process of the communication cable. The production process of the communication cable comprises the following steps: the first step, ingredient preparation, the second step, extrusion molding, the third step, cooling and shaping, the fourth step, cable core production, the fifth step, insulation layer and cable core combination, the sixth step, winding and cutting, the seventh step, packaging and inspection, the formula of the insulation layer of the communication cable can achieve excellent insulation performance, high temperature resistance, mechanical strength, corrosion resistance, flame retardant performance and environmental sustainability and other technical effects, improve the quality and reliability of the communication cable, and meet the high requirements of the modern communication industry for cable performance. The production process of the communication cable can achieve the technical effects of improving product quality, improving production efficiency, reducing production costs, and enhancing product performance and consistency.

Description

Technical Field

[0001] The invention relates to the production field of communication cables, and in particular to a formula of an insulation layer of a communication cable and a production process of the communication cable. Background Art

[0002] Communication cables are an important part of modern communication systems and are used to transmit electrical signals and data. In communication systems, the insulation layer of cables plays a vital role. It needs to ensure stable signal transmission, prevent current leakage and interference, and also withstand external stress and environmental factors. Therefore, the selection of insulation layer materials and production processes for communication cables is crucial to the performance and stability of the cables.

[0003] In the traditional manufacturing process of communication cables, the insulation layer is usually made of a single polymer material, such as polyethylene, polypropylene, etc. Although these materials are low in cost, their insulation performance, high temperature resistance, mechanical strength and other aspects often cannot meet the requirements of modern communication systems. In addition, traditional insulation layer materials are also susceptible to chemical corrosion and moisture erosion, resulting in cable performance degradation and damage. Therefore, developing an insulation layer formula with excellent performance is an urgent problem to be solved in the field of communication cable manufacturing.

[0004] With the continuous development of modern communication technology, the performance requirements of communication cables are constantly increasing. Traditional insulation materials can no longer meet the requirements of modern communication systems. Therefore, developing an insulation formula with excellent performance is an urgent problem to be solved.

[0005] Existing insulation layer formulas usually use a single polymer material, which has certain limitations in terms of insulation performance, high temperature resistance, mechanical strength, etc. In addition, these materials may also have problems with chemical corrosion and moisture erosion, resulting in cable performance degradation and damage.

[0006] In addition, the existing insulation layer formula lacks consideration of the composite properties of the materials and cannot meet the multiple performance requirements of modern communication systems for cables. Therefore, it is an important task to develop a new insulation layer formula that has excellent insulation performance, high temperature resistance, mechanical strength, and resistance to chemical corrosion and moisture erosion.

[0007] The traditional production process of communication cables usually adopts the extrusion molding method, that is, the insulating material is extruded into a continuous insulating layer through an extruder, and then combined with the cable core. Although this production process is simple and easy, it has some defects.

[0008] First, bubbles and internal stress are easily generated during the extrusion process, affecting the performance and life of the insulation layer. This is mainly because the material flow is uneven during the extrusion process, and the cooling speed is too fast, which leads to the generation of internal stress in the material. These bubbles and internal stress may cause the insulation layer to crack and fall off, seriously affecting the service life and performance stability of the cable.

[0009] Secondly, it is difficult to control parameters such as temperature, pressure and speed during the extrusion process, resulting in poor uniformity and continuity of the insulation material. If the temperature is too high or the pressure is too high, the material may decompose and deform; if the speed is too fast, the material flow may be unstable and vortexes may appear. These problems will affect the quality and performance of the insulation material.

[0010] Finally, the traditional production process lacks effective control over the manufacturing accuracy of the cable core and the bonding strength between the insulation layer and the cable core, resulting in unstable product quality. In the traditional production process, the cable core is usually made by methods such as wire drawing or injection molding, which may cause uneven diameter and structure of the cable core due to factors such as impure materials or temperature fluctuations. In addition, in the traditional production process, the bonding strength between the insulation layer and the cable core is mainly achieved by methods such as mechanical pressure or hot melt, which have poor stability and are prone to insufficient bonding or falling off due to factors such as improper operation or material changes.

[0011] Therefore, the production process of traditional communication cables has defects such as easy generation of bubbles and internal stress during extrusion molding, difficulty in parameter control, lack of effective control of cable core manufacturing accuracy and the bonding force between the insulation layer and the cable core, resulting in unstable product quality. In order to improve product quality and production efficiency and reduce production costs, enhance product performance and consistency, and promote the sustainable development of the communication industry, a new production process for communication cables must be developed. Summary of the invention

[0012] The first purpose of the present invention is to solve the above-mentioned defects and provide a formula for the insulation layer of a communication cable, which ensures that the insulation layer of the communication cable has good insulation performance, high temperature resistance, mechanical strength, corrosion resistance and flame retardancy, and solves the technical problem that the insulation layer of the communication cable in the prior art has a single function and cannot meet market demand.

[0013] The object of the present invention is achieved in the following ways:

[0014] A formulation for an insulating layer of a communication cable, the formulation comprising the following components in parts by weight:

[0015] Polyimide resin: 20-30 parts;

[0016] Polytetrafluoroethylene resin: 10-20 parts;

[0017] Silicone resin: 5-10 parts;

[0018] Nano-alumina powder: 5-10 parts;

[0019] Carbon nanotubes: 3-5 parts;

[0020] Glass fiber: 10-20 parts;

[0021] Polyethylene terephthalate: 5-10 parts;

[0022] Polycarbonate: 5-10 parts;

[0023] Polyethylene: 5-10 parts;

[0024] Polypropylene: 5-10 parts;

[0025] Polyvinyl chloride: 5-10 parts;

[0026] Polyamide: 5-10 parts;

[0027] Polyester: 5-10 parts;

[0028] Polyurethane: 5-10 parts;

[0029] Epoxy resin: 5-10 parts.

[0030] Furthermore, the formulation consists of the following components in parts by weight:

[0031] The weight portion of polyimide resin is 28 parts, the weight portion of polytetrafluoroethylene resin is 12 parts, the weight portion of silicone resin is 6 parts, the weight portion of nano-alumina powder is 6 parts, the weight portion of carbon nanotubes is 3 parts, the weight portion of glass fiber is 15 parts, the weight portion of polyethylene terephthalate is 8 parts, the weight portion of polycarbonate is 7 parts, the weight portion of polyethylene is 9 parts, the weight portion of polypropylene is 8 parts, the weight portion of polyvinyl chloride is 9 parts, the weight portion of polyamide is 7 parts, the weight portion of polyester is 10 parts, the weight portion of polyurethane is 5 parts, and the weight portion of epoxy resin is 8 parts.

[0032] The beneficial effects produced by the formula of the insulation layer of a communication cable of the present invention are:

[0033] 1) Excellent insulation performance: The formula uses high-performance insulating materials such as polyimide resin and polytetrafluoroethylene resin, which makes the insulation layer have excellent insulation performance, can effectively isolate electrical signals, and prevent current leakage and interference;

[0034] 2) Good high temperature resistance: Silicone resin and nano-alumina powder are added to the insulation layer to improve the high temperature resistance of the insulation layer, and it can maintain stable electrical and mechanical properties in high temperature environments;

[0035] 3) Excellent mechanical strength: Reinforcement materials such as glass fiber and carbon nanotubes are added to the formula, which makes the insulation layer have excellent tensile strength and compressive strength, able to withstand external stress and extrusion force, and maintain the integrity of the cable;

[0036] 4) Good corrosion resistance: Corrosion-resistant materials such as polyethylene terephthalate and polycarbonate are added to the insulation layer, which enables the insulation layer to resist chemical corrosion and moisture erosion and maintain long-term stability and reliability;

[0037] 5) Good flame retardant performance: The insulation layer uses materials such as polyamide, polyester and polyurethane with good flame retardant performance, which makes the cable difficult to burn when encountering a fire, reducing the risk of fire spreading;

[0038] 6) Environmentally friendly and sustainable: The materials used in the formula are all environmentally friendly and sustainable, do not contain harmful substances, meet environmental protection standards, and are conducive to promoting the sustainable development of the communications industry.

[0039] The formula of the insulation layer of the communication cable can achieve excellent insulation performance, high temperature resistance, mechanical strength, corrosion resistance, flame retardancy and environmental sustainability and other technical effects, which improves the quality and reliability of communication cables and meets the high requirements of the modern communication industry for cable performance.

[0040] The second purpose of the present invention is to solve the above-mentioned defects and provide a production process for communication cables, which can improve product quality, improve production efficiency, reduce production costs, enhance product performance and consistency, and solve the technical problems of low production efficiency and high production cost of communication cables in the prior art.

[0041] The production process of the communication cable comprises the following steps:

[0042] The first step is to prepare the ingredients by using a metering device, according to the formula ratio of the insulation layer of a communication cable in claim 1 or 2, mixing polyimide resin, polytetrafluoroethylene resin, silicone resin, nano-alumina powder, carbon nanotubes, glass fiber, polyethylene terephthalate, polycarbonate, polyethylene, polypropylene, polyvinyl chloride, polyamide, polyester, polyurethane and epoxy resin to obtain an insulation layer material, and controlling the accuracy of the metering device to ensure the accuracy of the ingredient ratio;

[0043] The second step is extrusion molding. The insulation layer material is extruded by an extruder. The temperature of the extruder is controlled at 150-250°C, the pressure is controlled at 10-20MPa, and the speed is controlled at 5-10rpm. By controlling the parameters of temperature, pressure and speed, the insulation layer material is ensured to be uniform and continuous during the extrusion process.

[0044] The third step is cooling and shaping. The extruded insulation layer material is cooled and shaped through a cooling water tank. The temperature of the cooling water tank is controlled at 20-30°C and the flow rate is 1-2m / s. By controlling the parameters of temperature and flow rate, the insulation layer material is ensured to be cooled quickly and evenly.

[0045] The fourth step is cable core production. According to the preset cable specifications and design requirements, the cable core is produced using corresponding equipment, and the diameter, structure and material of the cable core are controlled to meet the performance requirements of the communication cable;

[0046] Step 5: Combine the insulation layer and the cable core. Combine the cooled insulation layer material with the prepared cable core. Control the tension, temperature and speed during the combination process to ensure that the insulation layer and the cable core are tightly combined without bubbles.

[0047] Step 6: Reeling and cutting: Use the reeling machine and cutting equipment to reel and cut the assembled cables, control the reeling tension at 5-10N, and control the cutting length error within ±0.5mm;

[0048] Step 7: Packaging and inspection: Use a vacuum packaging machine to package the cut cables, and control the working air pressure of the packaging machine at 0.5-1.0 bar. Then, conduct electrical and mechanical performance inspections to ensure product quality.

[0049] Furthermore, in the third step, after cooling and shaping, the insulating layer material needs to be surface treated by spraying a layer of anti-corrosion and wear-resistant coating on the surface of the insulating layer material using a spraying device to improve its corrosion resistance and wear resistance.

[0050] The beneficial effects of the production process of the communication cable of the present invention are:

[0051] 1) Improve the uniformity and continuity of the insulation layer material: By precisely controlling the temperature, pressure and speed of the extruder, the insulation layer material remains uniform and continuous during the extrusion process, thereby improving the stability and consistency of the insulation layer;

[0052] 2) Optimize the cooling effect of the insulation layer material: by precisely controlling the temperature and flow rate of the cooling water tank, the insulation layer material is ensured to be cooled quickly and evenly, which reduces the internal stress generated during the cooling process and improves the performance and life of the insulation layer;

[0053] 3) Improve the manufacturing accuracy of cable cores: By using corresponding equipment to make cable cores, the diameter, structure and material of the cable cores are controlled to meet the performance requirements of communication cables, and the accuracy and stability of the cable cores are improved;

[0054] 4) Enhance the bonding strength between the insulation layer and the cable core: By precisely controlling the tension, temperature and speed during the assembly process, the insulation layer and the cable core are ensured to be tightly bonded and free of bubbles, thereby enhancing the bonding strength and durability between the insulation layer and the cable core;

[0055] 5) Improve the cutting accuracy and consistency of cables: By precisely controlling the winding tension and cutting length error, the cables are cut neatly and consistently, thus improving the appearance quality and consistency of the cables;

[0056] 6) Improve product packaging quality and efficiency: By using a vacuum packaging machine for packaging and controlling the working air pressure of the packaging machine within an appropriate range, ensure that the product is intact during the packaging process and is easy to store and transport;

[0057] The production process of the patent of this invention can achieve the technical effects of improving product quality, increasing production efficiency, reducing production costs, and enhancing product performance and consistency. DETAILED DESCRIPTION

[0058] The present invention is further described in detail below in conjunction with specific implementation modes.

[0059] In this embodiment, the implementation scheme of the formula of the insulation layer of a communication cable is as follows:

[0060] 1. Ingredients preparation

[0061] 1. Accurately weigh various raw materials according to the following formula ratio:

[0062] Polyimide resin: 20-30 parts, preferably 28 parts;

[0063] Polytetrafluoroethylene resin: 10-20 parts, preferably 12 parts;

[0064] Silicone resin: 5-10 parts, preferably 6 parts;

[0065] Nano-alumina powder: 5-10 parts, preferably 6 parts;

[0066] Carbon nanotubes: 3-5 parts, preferably 3 parts;

[0067] Glass fiber: 10-20 parts, preferably 15 parts;

[0068] Polyethylene terephthalate: 5-10 parts, preferably 8 parts;

[0069] Polycarbonate: 5-10 parts, preferably 7 parts;

[0070] Polyethylene: 5-10 parts, preferably 9 parts;

[0071] Polypropylene: 5-10 parts, preferably 8 parts;

[0072] Polyvinyl chloride: 5-10 parts, preferably 9 parts;

[0073] Polyamide: 5-10 parts, preferably 7 parts;

[0074] Polyester: 5-10 parts, preferably 10 parts;

[0075] Polyurethane: 5-10 parts, preferably 5 parts;

[0076] Epoxy resin: 5-10 parts, preferably 8 parts.

[0077] 2. Mix all the raw materials together and use a stirrer to fully stir them to ensure that all the materials are evenly dispersed. The stirring speed should be controlled at 200-300 rpm and the stirring time should be no less than 30 minutes.

[0078] 3. Put the fully stirred mixture into a clean container, mark and record the ingredients. Keep the container clean to avoid impurities.

[0079] 2. Extrusion molding

[0080] 1. Place the mixed ingredients into the hopper of the extruder. Make sure the hopper is well sealed to prevent material leakage.

[0081] 2. Adjust the temperature, pressure and speed of the extruder to suit the characteristics of the insulation material. Adjust according to the actual situation to ensure that the material is fully melted and flows evenly. The temperature of the extruder is set to 230-270℃, the pressure is 150-250MPa, and the speed is 20-40 rpm.

[0082] 3. Start the extruder and control the operating parameters of the extruder to ensure that the insulation material remains uniform and continuous during the extrusion process. Observe the insulation material at the extruder outlet to ensure that its shape and quality meet the requirements.

[0083] 4. Adjust the extruder parameters to obtain the best insulation material performance. Adjust according to the actual effect to achieve the best effect.

[0084] 3. Cooling and shaping

[0085] 1. Introduce the extruded insulation material into the cooling water tank. Pay attention to controlling the water temperature of the cooling water tank to ensure good cooling effect and no damage to the material. The water temperature of the cooling water tank is set to 15-25℃.

[0086] 2. Control the water flow rate and temperature of the cooling water tank to cool the insulation layer material quickly and evenly. Observe the cooling process of the insulation layer material to ensure that its shape is stable and without deformation. The water flow rate is controlled at 1-2m / s.

[0087] 3. Adjust the water flow rate and temperature of the cooling water tank to obtain the best cooling effect. Adjust according to the actual effect to achieve the best effect.

[0088] 4. After drying, the insulation material is quality checked to ensure that it meets the requirements. Materials that do not meet the requirements are reworked or scrapped. Use a vacuum packaging machine for packaging.

[0089] In this embodiment, the implementation plan of the production process of the communication cable is as follows: the production process mainly includes the steps of ingredient preparation, extrusion molding, cooling and shaping, cable core production, insulation layer and cable core combination, winding and cutting, packaging and inspection. The following are the specific implementation plans and precautions for each step.

[0090] 1. Ingredients preparation

[0091] In this step, the ingredients are prepared according to the implementation plan of the formula of the insulation layer of a communication cable, and the polyimide resin, polytetrafluoroethylene resin, silicone resin, nano-alumina powder, carbon nanotubes, glass fiber, polyethylene terephthalate, polycarbonate, polyethylene, polypropylene, polyvinyl chloride, polyamide, polyester, polyurethane and epoxy resin are accurately weighed and mixed evenly using metering equipment to obtain the insulation layer material. Key points include: 1. Ensure the accuracy of the metering equipment to accurately control the proportion of ingredients;

[0092] 2. Ensure the purity and quality of raw materials and avoid impurities and contamination;

[0093] 3. Stir thoroughly during the mixing process to ensure that all raw materials are evenly dispersed.

[0094] 2. Extrusion molding

[0095] In the extrusion step, the insulation material is extruded using an extruder. Key parameters include temperature, pressure, and speed. Specific requirements are as follows:

[0096] 1. Temperature: controlled at 150-250℃ to adapt to the characteristics of the material and ensure the normal operation of the equipment;

[0097] 2. Pressure: controlled at 10-20MPa to ensure full melting and uniform flow of the material;

[0098] 3. Rotation speed: controlled at 5-10rpm to control the extrusion speed and shape of the material.

[0099] 3. Cooling and shaping

[0100] In the cooling and shaping step, the extruded insulation material will be cooled through a cooling water tank. Key parameters include the water tank temperature and flow rate. Specific requirements are as follows:

[0101] 1. Water tank temperature: controlled at 20-30℃ to avoid deformation caused by excessive cooling of the material;

[0102] 2. Flow speed: controlled at 1-2m / s to ensure uniform cooling of the material.

[0103] After cooling and shaping, the insulating layer material needs to be surface treated by spraying a layer of anti-corrosion and wear-resistant coating on the surface of the insulating layer material using spraying equipment to improve its corrosion resistance and wear resistance.

[0104] 4. Cable core production

[0105] In the cable core production step, the cable core will be produced using appropriate equipment according to the preset cable specifications and design requirements. Key considerations include:

[0106] 1. Control the diameter, structure and material of the cable core to meet the performance requirements of the communication cable; 2. Ensure that the surface of the cable core is smooth and clean to avoid impurities and pollution.

[0107] 5. Combination of insulation layer and cable core

[0108] In the insulation layer and cable core combination step, the cooled insulation layer material is combined with the prepared cable core. Key considerations include:

[0109] 1. Control the tension, temperature and speed during the assembly process to ensure that the insulation layer is tightly combined with the cable core without bubbles;

[0110] 2. Ensure that the surface of the assembled cable is smooth and flat without scratches or dents.

[0111] 6. Rolling and cutting

[0112] In the winding and cutting steps, the combined cables will be wound and cut using a winding machine and cutting equipment. Key parameters include winding tension and cutting length error. Specific requirements are as follows:

[0113] 1. Reeling tension: controlled at 5-10N to ensure the quality and integrity of the cable reeling;

[0114] 2. Cutting length error: controlled within ±0.5mm to ensure the uniformity and standardization of products.

[0115] 7. Packaging and Inspection

[0116] In the packaging and inspection steps, the cut cables will be packaged using a vacuum packaging machine, and the working pressure of the packaging machine will be controlled at 0.5-1.0 bar. The electrical and mechanical properties will then be inspected to ensure product quality. Key considerations include:

[0117] 1. Ensure the cleanliness and integrity of the packaging to prevent the product from being damp and contaminated;

[0118] 2. Conduct electrical and mechanical performance tests in accordance with relevant standards and specifications to ensure that the products meet the industry standards for communication cables.

[0119] The above contents are further detailed descriptions of the present invention in combination with specific preferred embodiments, and it cannot be determined that the specific implementation of the present invention is limited to these descriptions. For ordinary technicians in the technical field to which the present invention belongs, several simple deductions or substitutions can be made without departing from the concept of the present invention, which should be regarded as the protection scope of the present invention.

Claims

1. A production process for communication cables, characterized in that: The production process includes the following steps: The first step is to prepare the ingredients. Use a metering device to form a formula for the insulation layer of a communication cable according to the following weight proportions: polyimide resin: 20-30 parts; polytetrafluoroethylene resin: 10-20 parts; silicone resin: 5-10 parts; nano-alumina powder: 5-10 parts; carbon nanotubes: 3-5 parts; glass fiber: 10-20 parts; polyethylene terephthalate: 5-10 parts; polycarbonate: 5-10 parts; polyethylene: 5-10 parts; polypropylene: 5-10 parts; polyvinyl chloride: 5-10 parts; polyamide: 5-10 parts; polyester: 5-10 parts; polyurethane: 5-10 parts; epoxy resin: 5-10 parts; The polyimide resin, polytetrafluoroethylene resin, silicone resin, nano-alumina powder, carbon nanotubes, glass fiber, polyethylene terephthalate, polycarbonate, polyethylene, polypropylene, polyvinyl chloride, polyamide, polyester, polyurethane and epoxy resin are uniformly mixed to obtain an insulating layer material, and the accuracy of the metering equipment is controlled to ensure the accuracy of the proportion of the ingredients; The second step is extrusion molding. The insulation layer material is extruded by an extruder. The temperature of the extruder is controlled at 150-250°C, the pressure is controlled at 10-20MPa, and the speed is controlled at 5-10rpm. By controlling the parameters of temperature, pressure and speed, the insulation layer material is ensured to be uniform and continuous during the extrusion process. The third step is cooling and shaping. The extruded insulation layer material is cooled and shaped through a cooling water tank. The temperature of the cooling water tank is controlled at 20-30°C and the flow rate is 1-2m / s. By controlling the parameters of temperature and flow rate, the insulation layer material is ensured to be cooled quickly and evenly. The fourth step is cable core production. According to the preset cable specifications and design requirements, the cable core is produced using corresponding equipment, and the diameter, structure and material of the cable core are controlled to meet the performance requirements of the communication cable; Step 5: Combine the insulation layer and the cable core. Combine the cooled insulation layer material with the prepared cable core. Control the tension, temperature and speed during the combination process to ensure that the insulation layer and the cable core are tightly combined without bubbles. Step 6: Reeling and cutting: Use the reeling machine and cutting equipment to reel and cut the assembled cables, control the reeling tension at 5-10N, and control the cutting length error within ±0.5mm; Step 7: Packaging and inspection: Use a vacuum packaging machine to package the cut cables, and control the working air pressure of the packaging machine at 0.5-1.0 bar. Then, conduct electrical and mechanical performance inspections to ensure product quality.

2. The production process of communication cables according to claim 1, characterized in that: In the third step, after cooling and shaping, the insulating layer material needs to be surface treated by spraying a layer of anti-corrosion and wear-resistant coating on the surface of the insulating layer material using a spraying device to improve its corrosion resistance and wear resistance.