Polyvinyl chloride insulated electronic wire and manufacturing method thereof

Abstract

The invention relates to the technical field of wires and cables, and discloses a polyvinyl chloride insulated electronic wire and a manufacturing method thereof, and the polyvinyl chloride insulated electronic wire is composed of the following structures: a conductor; twisted pair wire cores; a first isolation layer; a cable core; a second isolation layer; a shielding layer; and an outer sheath. The invention discloses a manufacturing method of a polyvinyl chloride insulated electronic wire. The manufacturing method comprises the following steps: S1, manufacturing a conductor; s2, wrapping with an insulating layer; s3, performing pair twisting; s4, wrapping with a first isolation layer; s5, manufacturing a cable core; s6, wrapping with a second isolation layer; s7, weaving a shielding layer; and S8, wrapping with an outer sheath. The polyvinyl chloride insulated electronic wire and the manufacturing method thereof have the following beneficial effects: high-efficiency electric conduction and long service life are realized; the electrical insulation and heat resistance are excellent; the signal transmission quality is excellent; the structural stability and the stretching resistance are enhanced; and the manufacturing process is efficient.

Description

Technical Field

[0001] The invention relates to the technical field of electric wires and cables, in particular to a polyvinyl chloride insulated electronic wire and a manufacturing method thereof. Background Art

[0002] Polyvinyl chloride insulated electronic wire (PVC insulated electronic wire) is a kind of wire and cable widely used for internal connection of electronic and electrical equipment. PVC insulated electronic wire is mainly composed of single or multiple conductive copper wires, and its surface is wrapped with a layer of polyvinyl chloride (PVC) insulator to prevent contact with the conductor, ensuring electrical safety and stability of signal transmission.

[0003] Traditional copper conductors are susceptible to oxidation during long-term use, resulting in a decrease in conductivity, affecting power transmission efficiency and equipment life.

[0004] At the same time, the electronic wire insulation materials in the prior art are deficient in heat resistance, flame retardancy and insulation strength, are difficult to adapt to the complex and changing use environment, and pose safety hazards.

[0005] In the field of high-speed data transmission and signal transmission, traditional electronic wires are susceptible to electromagnetic interference, which affects the stability and clarity of signal transmission.

[0006] The structural design of some electronic wires is not reasonable, which may lead to problems such as breakage and deformation during long-term use or in harsh environments, affecting the use effect.

[0007] In view of the above background, the present invention provides a polyvinyl chloride insulated electronic wire and a manufacturing method thereof. Summary of the invention

[0008] 1. Technical issues to be solved

[0009] In view of the deficiencies in the prior art, the present invention provides a polyvinyl chloride insulated electronic wire and a method for manufacturing the same to solve the problems raised in the above background technology.

[0010] (II) Technical solution

[0011] To achieve the above object, the present invention provides the following technical solutions: a polyvinyl chloride insulated electronic wire, the outer diameter of the electronic wire ranges from 8.2 mm to 9.2 mm;

[0012] The electronic wire is composed of the following structures in sequence:

[0013] Conductor: It is composed of no less than three strands of tinned copper monofilaments. The tinned copper monofilaments maintain the good conductivity of copper itself. Due to the presence of the tin layer, its conductivity is further improved, so it is suitable for electronic and electrical equipment, cables, electromagnetic coils, electric heaters and other occasions that require efficient conductivity. At the same time, the tin layer can effectively prevent the copper wire from being exposed to the air and oxidized to form copper green with poor conductivity, chemical formula Cu2(OH)2CO3, thereby greatly extending the service life of the copper wire.

[0014] Insulation layer: Made of polyvinyl chloride material, tightly and evenly wrapped around the conductor to form an insulated wire core structure. The insulation layer provides electrical insulation and heat resistance for the conductor, preventing current leakage and short circuit risks.

[0015] Twisted pair core: It is made of two insulated cores twisted together using a precision twisting process.

[0016] The first isolation layer: tightly wrapped around the outside of the twisted core, using high-strength polyester tape material, effectively isolates the electromagnetic interference between the twisted cores and improves the overall signal transmission quality. The high-strength polyester tape material is made of new polyethylene terephthalate material containing silicon oxide, light calcium carbonate, maleic anhydride grafted POE elastomer, light stabilizer and epoxy styrene / acrylic oligomer additives. The components and functions are as follows:

[0017] Polyethylene terephthalate (PET): As the main component of polyester tape, PET has excellent physical and mechanical properties, high strength, can withstand large tension and pressure, and is not easy to break.

[0018] additive:

[0019] Silicon oxide: Enhances the hardness and wear resistance of polyester belts.

[0020] Light calcium carbonate: improve the processing performance of polyester tape and reduce costs.

[0021] Maleic anhydride grafted POE elastomer: improves the elasticity and flexibility of polyester tapes.

[0022] Light stabilizer (such as Light Stabilizer 2020): prevents polyester tape from degrading under light and maintains its long-term stability.

[0023] Epoxy Styrene / Acrylic Oligomer: Improves weather and chemical resistance of polyester tapes.

[0024] Cable core: It is composed of no less than three twisted wire cores wrapped with the first isolation layer and twisted together again. The internal gap of the cable core is accurately filled with filling ropes to enhance the structural stability and tensile resistance of the cable core.

[0025] Second isolation layer: Wrapped around the outside of the cable core, it is composed of aluminum-plastic composite tape, which not only provides additional shielding effect, but also enhances the resistance of electronic wires to external electromagnetic interference. The aluminum-plastic composite tape is made of an aluminum base tape coated with ethylene-methacrylic acid copolymer (EMAA) resin adhesive film on one or both sides.

[0026] Shielding layer: Located outside the second isolation layer, it is made of tinned copper wire braided structure, which further enhances the shielding performance of the electronic wire and ensures the purity and safety of signal transmission.

[0027] When manufacturing the tinned copper wire braided structure, the braiding angle of the braiding equipment is set to 30-60° according to the design requirements of the cable and the performance indicators of the shielding layer to ensure the tightness and uniformity of the braided layer, while the braiding density is controlled to be above 80% to improve the shielding effect.

[0028] Outer sheath: tightly and evenly wrapped around the outside of the shielding layer, made of polyvinyl chloride material, provides reliable mechanical protection and environmental resistance for the electronic wire and prolongs its service life.

[0029] Preferably, the insulating layer and the outer sheath are both made of high-quality polyvinyl chloride material after chemical-physical dual modification, and the chemical-physical dual modification method of the high-quality polyvinyl chloride material is:

[0030] Prepare polyvinyl chloride raw materials, and use water phase suspension method or gas phase method to chemically modify and chlorinate the polyvinyl chloride raw materials, so that the chlorine content in the material is increased to 65%, and obtain chlorinated polyvinyl chloride materials. The chlorinated modified PVC (CPVC) has higher heat resistance, flame retardant properties and tensile strength. CPVC can be used to produce insulating materials with high heat resistance requirements, but its impact strength may be reduced. Therefore, inorganic or organic fillers (such as wood powder, metal powder, calcium carbonate, etc.) are added to the chlorinated polyvinyl chloride material to physically modify the material, thereby obtaining high-quality polyvinyl chloride materials. This high-quality polyvinyl chloride material that has been physically and chemically modified in this scheme has higher heat resistance, flame retardant properties and tensile strength, while reducing the specific gravity of the material and improving other properties of the material, such as adding wood powder filler to reduce the specific gravity, close to wood; adding metal powder (such as copper powder, aluminum powder) to improve conductivity; adding calcium carbide to increase hardness and reduce costs.

[0031] A method for manufacturing a polyvinyl chloride insulated electronic wire, the method is used to manufacture the above-mentioned polyvinyl chloride insulated electronic wire, the method comprising the following steps:

[0032] S1: Conductor production

[0033] The conductor is composed of not less than three strands of tinned copper monofilaments;

[0034] S2: Insulation wrap

[0035] The modified high-quality polyvinyl chloride material is tightly and evenly wrapped around the outside of the conductor as an insulating layer;

[0036] S3: Twisted Pair

[0037] Two insulated wire cores are twisted into a pair of twisted wire cores through a precision twisting process;

[0038] S4: First isolation layer wrapping

[0039] Tightly wrap the twisted wire core with high-strength polyester tape material as the first isolation layer;

[0040] S5: Cable core production

[0041] Precision twist at least three twisted pair cores wrapped with the first isolation layer again, and use filler ropes to accurately fill the internal gaps of the cable core;

[0042] S6: Second isolation layer wrapping

[0043] Wrap an aluminum-plastic composite tape around the outside of the cable core as a second isolation layer;

[0044] S7: Shield braid

[0045] Tinned copper wires are braided outside the second isolation layer to form a shielding layer;

[0046] S8: Outer sheath wrap

[0047] The modified high-quality polyvinyl chloride material is tightly and evenly wrapped outside the shielding layer as an outer sheath.

[0048] Preferably, the filling rope precise filling process comprises:

[0049] First, according to the design requirements of the cable, the cross-sectional area, number of twisted cores and diameter of the cable are measured, and the size of the gap inside the cable core is calculated, so as to calculate the required amount of filling rope. Then, according to the calculation results, a filling device is used to evenly and accurately fill the quantitative filling rope into the gap between the cores. The filling device uses an adjustable filling nozzle to control the flow and distribution of the filling rope. At the same time, after the filling is completed, the cable is compacted using a compaction device to ensure that the filling rope fits tightly with the core and eliminates possible gaps. The filling rope is a polypropylene mesh belt, a low-smoke halogen-free flame-retardant rope or a glass fiber rope.

[0050] Preferably, the wrapping process includes:

[0051] Clean the cable core to remove oil and impurities on the surface to ensure that the aluminum-plastic composite tape can fit tightly on the cable core, and set the overlap rate of the wrapping equipment to 30%-50% to ensure the tightness and uniformity of the wrapping layer.

[0052] Preferably, the precision twisting process includes:

[0053] The wires to be twisted are pre-cleaned and reduced in diameter to remove surface dirt and oxides, and are twisted using a ship-frame-type stranding machine with a tension adjustment system. During the twisting process, a vernier caliper or micrometer is used to measure the diameter and pitch of the stranded wires, and the pitch change gear or electronic control system of the stranding machine is adjusted to achieve precise control of the pitch, thereby improving the tightness and stability of the stranded wires. After twisting, the wire body is annealed to eliminate internal stress and improve flexibility. The ship-frame-type stranding equipment has a higher rotation speed and a smaller wire curvature, which can improve the twisting efficiency and quality. The twisting operation of the wire core ensures the stability of the signal transmission process and improves the anti-interference ability of the wire, reducing signal attenuation and electromagnetic interference.

[0054] (III) Beneficial effects

[0055] Compared with the prior art, the present invention provides a polyvinyl chloride insulated electronic wire and a manufacturing method thereof, which has the following beneficial effects:

[0056] 1. The present invention adopts tinned copper monofilament as the conductor material, which not only maintains the excellent conductivity of copper itself, but also further improves the conductivity through the tin-plated layer, and effectively prevents the oxidation of the copper wire in the air, avoiding the formation of copper green with poor conductivity, thereby significantly extending the service life of the electronic wire;

[0057] 2. The insulating layer and outer sheath of the present invention are both made of high-quality polyvinyl chloride material, which has been physically and chemically modified and has higher heat resistance, flame retardancy and tensile strength, providing reliable electrical insulation and heat-resistant protection for the electronic wire, ensuring the stable operation of the electronic wire in various environments.

[0058] 3. The present invention effectively isolates the electromagnetic interference between the twisted wire cores by introducing the first isolation layer and the high-strength polyester tape material, thereby improving the overall signal transmission quality. At the same time, the shielding layer of the tinned copper wire braided structure further enhances the shielding performance of the electronic wire, ensuring the purity and safety of the signal transmission.

[0059] 4. The internal gaps of the cable core are filled with polypropylene mesh tape, low-smoke halogen-free flame-retardant rope or glass fiber rope through a precise filling process, which enhances the structural stability and tensile strength of the cable core and improves the overall mechanical properties of the electronic wire.

[0060] 5. The precision twisting process, precise filling process and wrapping process used in the manufacturing process improve the compactness and uniformity of the wire manufacturing, make the wire performance more stable, and improve the durability of the wire when used outdoors. At the same time, the twisting operation of the wire core ensures the stability of the signal transmission process and improves the anti-interference ability of the wire, reducing signal attenuation and electromagnetic interference. DETAILED DESCRIPTION

[0061] The technical solutions in the embodiments of the present invention are described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0062] The following are several examples of polyvinyl chloride insulated electronic wires:

[0063] Example 1: Special polyvinyl chloride insulated electronic wire

[0064] Application scenario: control system for low temperature resistant occasions

[0065] Technical features:

[0066] Conductor: It is composed of tinned copper monofilaments bundled together, conforming to the 5th type of tinned copper conductor specified in GB / T3956, and the bundled pitch diameter ratio is 23.

[0067] Insulation layer: The core is made of extruded insulation material with a nominal thickness of 0.76mm, an average thickness not less than the nominal thickness, and a thickness of not less than 0.69mm at the thinnest point.

[0068] Twisted pair core: two insulated wire cores twisted together.

[0069] The first isolation layer: A layer of polyester tape with a thickness of 0.04mm is wrapped around the twisted wire core, and the overlapping width of the wrapping is not less than 5mm.

[0070] Cable core: It is composed of multiple twisted wire cores wrapped in the first isolation layer and then twisted together, and the gaps in the cable core are filled with filling ropes.

[0071] Second isolation layer: A layer of aluminum-plastic composite tape with a width of 15-25mm and a thickness of 0.05mm is wrapped around the cable core. The overlapping width of the wrapping is not less than 5mm, and the aluminum side faces outwards during wrapping.

[0072] Shielding layer: Made of tinned copper wire braided structure, the single wire diameter is 0.15mm, the braiding angle is 55°~70°, and the unidirectional coverage is 0.55~0.70.

[0073] Outer sheath: It is made of extruded -40℃ low temperature resistant, oil resistant and flame retardant polyvinyl chloride sheath material with a thickness of 0.85mm.

[0074] Beneficial effects: The electronic wire of this embodiment has excellent technical performance, and is particularly suitable for control systems in low-temperature resistant occasions, and has good electrical insulation performance, low-temperature resistance and flame retardancy.

[0075] Example 2: Composite modified polyvinyl chloride insulated wire

[0076] Application scenario: Power transmission under extreme environmental conditions

[0077] Technical features:

[0078] Insulation layer: Composite modified polyvinyl chloride material made of polyvinyl chloride, dipentaerythritol, acetyl tributyl citrate, liquid paraffin, silicic acid coprecipitated lead silicate, zinc stearate, barium stearate, diphenol propane, calcium carbonate, carbon black and polyimide. This material has excellent mechanical properties, impact resistance, heat resistance and flame retardancy.

[0079] Conductor: High-purity oxygen-free copper wire or tinned copper wire is used to ensure excellent conductivity.

[0080] Filling and isolation: The internal space of the cable core is accurately filled with high-performance filling materials to enhance structural stability and tensile resistance. The isolation layer is made of high-strength polyester tape or similar materials.

[0081] Shielding layer: According to the needs, you can choose tinned copper wire braided structure or aluminum foil Mylar tape and other shielding methods to effectively suppress electromagnetic interference.

[0082] Outer sheath: Made of composite modified polyvinyl chloride material which is the same or similar to the insulation layer, with excellent weather resistance and abrasion resistance.

[0083] Beneficial effects: The electric wire of this embodiment can significantly improve the service life and application safety in extreme environments, and is suitable for power transmission and signal transmission under various harsh environmental conditions.

[0084] Example 3: Ultra-low temperature polyvinyl chloride modified insulated wire

[0085] Application scenario: Power transmission and signal transmission in ultra-low temperature environment

[0086] Technical features:

[0087] Insulation material: Ultra-low temperature polyvinyl chloride modified material is used, which can still maintain excellent flexibility and electrical insulation properties at extremely low temperatures.

[0088] Conductor: Copper alloy or tinned copper wire with low resistivity and high conductivity is used as the conductor material.

[0089] Insulation layer: An insulation layer is added outside the insulation layer, using materials with high thermal insulation performance such as polyurethane foam to reduce heat loss and improve the performance of the cable in ultra-low temperature environments.

[0090] Outer sheath: Made of low-temperature resistant and wear-resistant materials to protect the internal structure and prevent damage to the cable from the external environment.

[0091] Beneficial effects: The electric wire of this embodiment can maintain stable electrical and mechanical properties in an ultra-low temperature environment, and is suitable for power transmission and signal transmission in extremely cold areas such as polar regions and high mountains.

[0092] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0093] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A polyvinyl chloride insulated electronic wire, characterized in that: It consists of the following structure: Conductor: Made of no less than three strands of tinned copper monofilaments; Insulation layer: Made of polyvinyl chloride material, tightly and evenly wrapped around the conductor to form an insulated wire core structure; Twisted pair core: It is made of two insulated cores twisted together using a precision twisting process; The first isolation layer: made of high-strength polyester tape, tightly wrapped around the outside of the twisted wire core; The high-strength polyester belt material is made of new polyethylene terephthalate material containing silicon oxide, light calcium carbonate, maleic anhydride grafted POE elastomer, light stabilizer and epoxy styrene / acrylic oligomer additives; Cable core: It is composed of no less than three twisted wire cores wrapped with the first isolation layer and twisted again with precision. The internal gap of the cable core is accurately filled with filling ropes; The filling rope is a polypropylene mesh belt, a low-smoke halogen-free flame-retardant rope or a glass fiber rope; The second isolation layer: wrapped around the outside of the cable core, composed of aluminum-plastic composite tape; The aluminum-plastic composite tape is made of an aluminum base tape coated with an ethylene-methacrylic acid copolymer resin adhesive film on one or both sides; Shielding layer: located outside the second isolation layer, made of tinned copper wire braided structure; When manufacturing the tinned copper wire braided structure, the braiding angle of the braiding equipment is set to 30-60°, and the braiding density is not less than 80%; Outer sheath: tightly and evenly wrapped around the shielding layer, made of polyvinyl chloride material; The insulating layer and the outer sheath are both made of high-quality polyvinyl chloride material that has been chemically and physically modified.

2. The polyvinyl chloride insulated electronic wire according to claim 1, characterized in that: The chemical-physical dual modification method of the high-quality polyvinyl chloride material is: Prepare polyvinyl chloride raw materials, and use a water phase suspension method or a gas phase method to chemically modify and chlorinate the polyvinyl chloride raw materials, so that the chlorine content in the materials is increased to 65%, thereby obtaining chlorinated polyvinyl chloride materials; Inorganic or organic fillers are added to chlorinated polyvinyl chloride materials to physically modify the materials, thereby obtaining high-quality polyvinyl chloride materials.

3. A method for manufacturing polyvinyl chloride insulated electronic wire, characterized in that: The manufacturing method is used to manufacture the polyvinyl chloride insulated electronic wire according to any one of claims 1 to 2, and the manufacturing method comprises the following steps: S1: Conductor production The conductor is composed of not less than three strands of tinned copper monofilaments; S2: Insulation wrap The modified high-quality polyvinyl chloride material is tightly and evenly wrapped around the outside of the conductor as an insulating layer; S3: Twisted Pair Two insulated wire cores are twisted into a pair of twisted wire cores through a precision twisting process; S4: First isolation layer wrapping Tightly wrap the twisted wire core with high-strength polyester tape material as the first isolation layer; S5: Cable core production Precision twisting again of at least three twisted wire cores wrapped with the first isolation layer, and using a filling device to accurately fill the gap inside the cable core with a filling rope; S6: Second isolation layer wrapping Wrap an aluminum-plastic composite tape around the outside of the cable core as a second isolation layer; S7: Shield braid Tinned copper wires are braided outside the second isolation layer to form a shielding layer; S8: Outer sheath wrap The modified high-quality polyvinyl chloride material is tightly and evenly wrapped outside the shielding layer as an outer sheath.

4. The method for manufacturing an electronic wire according to claim 3, characterized in that: The process of accurately filling the filling rope in the cable core manufacturing step S5 includes: The cross-sectional area, number of twisted cores and diameter of the cable are measured to calculate the size of the gap inside the cable core and thus the amount of filling rope required; According to the calculation results, a filling device is used to evenly and accurately fill a certain amount of filling rope into the gaps between the wire cores.

5. The method for manufacturing an electronic wire according to claim 3, characterized in that: The wrapping process in the second isolation layer wrapping in step S6 includes: Clean the cable core to remove oil and impurities on the surface to ensure that the aluminum-plastic composite tape can fit tightly on the cable core; Use wrapping equipment to wrap the aluminum-plastic composite tape around the outside of the cable core with an overlap rate of 30%-50% to ensure the tightness and uniformity of the wrapping layer.

6. The method for manufacturing an electronic wire according to claim 3, characterized in that: The precision twisting process in step S3 of twisting and step S5 of cable core production includes: The wires to be twisted are pre-cleaned and reduced in diameter to remove surface dirt and oxides, and are twisted using a ship-frame-type twisting machine with a tension adjustment system; During the stranding process, a vernier caliper or micrometer is used to measure the diameter and pitch of the stranded wire, and precise control of the pitch is achieved by adjusting the pitch change gear or electronic control system of the stranding machine; After twisting, the wire is annealed to eliminate internal stress and improve flexibility.

7. The method for manufacturing an electronic wire according to claim 3, characterized in that: In the step S5, the filling device in the cable core production uses an adjustable filling nozzle to control the flow and distribution of the filling rope; After filling is completed, use compaction equipment to compact the cable to ensure that the filling rope fits tightly against the core and eliminates any gaps that may exist.