Prefabricated branch cable for mobile use and process for producing the same

Abstract

The present application relates to the technical field of cable production, and particularly relates to a prefabricated branch cable for mobile use and a production process thereof, which comprises, from inside to outside, a connecting body formed by a main cable and a branch cable, a hot melt buffer layer, a tubular elastomer insulation fixing layer, an injection molding indication layer, a transparent polyester film layer and an elastomer injection molding insulation layer. The prefabricated branch cable for mobile use disperses the soft conductor into a peacock tail structure to disperse stress, is fixed by a hoop and is prevented from being broken; a hot melt tape is wound around a conductor branch connection to form a buffer layer, thereby further preventing the conductor from being broken; the elastomer material used for cable branch injection molding insulation enables the elastomer injection molding insulation layer to remain soft at -40 DEG C to 90 DEG C, the insulation resistance is greater than 500 M ohm after 5 million times of bending, and dynamic insulation reliability is greatly improved; the production process of the prefabricated branch cable for mobile use is controllable, red hot melt adhesive tape realizes injection molding filling visualization, and more than 15% of materials are saved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cable production, in particular to a prefabricated branch cable for mobile use and a production process thereof. BACKGROUND

[0002] The traditional prefabricated branch cable is designed for fixed laying, and has the following defects: difficulty in moving use of the fixed branch cable, frequent conductor breakage: stress concentration of the fixed connector when moving and bending, leading to fatigue fracture of the conductor; unstable insulation performance: frequent bending causes rapid aging and cracking of the insulation layer, loss of mechanical properties, waterproofness and electrical safety; no dedicated branch cable process for mobile use: the existing branch cable manufacturing process cannot solve the structural reliability problem under dynamic working conditions. SUMMARY

[0003] The technical problems to be solved by the present application are: traditional prefabricated branch cable prone to conductor breakage; unstable insulation performance; and no dedicated prefabricated branch cable manufacturing process for mobile use.

[0004] The technical solution adopted by the present application to solve the technical problems is: a prefabricated branch cable for mobile use, comprising, from inside to outside:

[0005] A connector formed by the main cable soft conductor, the branch cable soft conductor and the fixing clamp;

[0006] A hot melt buffer layer covering the connector;

[0007] A tubular elastomer insulation fixing layer sleeved outside the hot melt buffer layer;

[0008] A red hot melt tape covering the main cable, and a transparent polyester film layer covering the adjacent connector;

[0009] An elastomer injection molding insulation layer injection molded and completely covering the connector.

[0010] The hot melt buffer layer is an elastic hot melt adhesive with a width of 10-20mm and a thickness of 3-5mm, which is formed by melting and cooling; the connector is sleeved with a tubular elastomer insulation, the material of the tubular elastomer insulation is the same as that of the elastomer injection molding insulation layer, and an oven gun is used to heat the opening, which is melted together after being heated.

[0011] A production process of a prefabricated branch cable for mobile use, comprising the following steps:

[0012] S1: stripping the sheath layer and the insulation layer of the main cable and the branch cable, exposing the main cable soft conductor with a length of 5-10cm, and exposing the branch cable soft conductor with a length of 5-10cm;

[0013] S2 disperses the branch cable soft conductor into peacock tail shape, and the dispersion width matches the circumference of the main cable soft conductor;

[0014] S3 covers the branch cable soft conductor on the main cable soft conductor, and first spot-welds and fixes and then locks by using a copper clamp; a connecting body of the main cable soft conductor and the branch cable soft conductor is formed;

[0015] S4 winds an elastic sheet-shaped hot melt adhesive on the connecting body, and after heating and melting, the hot melt adhesive is rapidly cooled to form a hot melt buffer layer;

[0016] S5 sets a tubular elastic body insulation on the hot melt buffer layer, and uses a baking gun to heat the opening, and after the opening is heated, the opening is melted together;

[0017] S6 wraps 2-3 layers of transparent polyester film on adjacent connecting bodies, and winds 2-3 layers of red hot melt adhesive tape with a width of 10-20 mm at a position 3-5 cm away from the main cable sheath stripping position as an injection indication layer;

[0018] S7 places the connecting body into an injection mold, and injects an elastic body injection material to form an elastic body injection insulation layer;

[0019] S8 after water cooling for 3-5 minutes, the overflow is trimmed, and the natural cooling is performed to room temperature.

[0020] In S7, the injection material is melted, the injection indication layer is melted and overflowed from the mold gap, and the injection indication layer serves as a visual indication mark of the completion of injection filling.

[0021] In S4, the hot melt gun is heated, and then the cold wind is used for rapid cooling and shaping, and in S7, the injection thickness is 3-5 cm, and the high-temperature injection material melts through the transparent polyester film layer to fill the internal gap, so that the eccentricity problem of the injection insulation is prevented.

[0022] In S5, the material of the tubular elastic body insulation is the same as that of the elastic body injection insulation layer, so that the softness and stability of the electrical performance of the tubular insulation during frequent movement are ensured, the tubular insulation and the elastic body injection insulation layer are melted to form an integrated insulation, and the waterproof performance and the prevention of core breakage are further improved.

[0023] The elastic body injection material used in S7 is composed of the following components in percentage by mass: POE polyolefin elastomer 80%-85%, PES polyether sulfone 1%-3%, PVDF polyvinylidene fluoride 5%-8%, ESO epoxy soybean oil 2%-5%, naphthenic oil 4%-10%, EBS ethyl bis-stearamide 0.2%-0.5%, antioxidant 1010 0.15%-0.3%, and antioxidant 1076 0.05%-0.15%.

[0024] An elastic body material for cable branch injection insulation is composed of the following components in percentage by mass:

[0025] POE polyolefin elastomer 80%~85%;

[0026] PES polyether sulfone 1%~3%;

[0027] PVDF polyvinylidene fluoride 5%~8%;

[0028] ESO epoxy soybean oil 2%~5%;

[0029] Naphthenic oil 4%~10%;

[0030] EBS ethyl bis stearamide 0.2%~0.5%;

[0031] Antioxidant 1010 0.15%~0.3%;

[0032] Antioxidant 1076 0.05%~0.15%.

[0033] PES and PVDF as corrosion-resistant and insulation performance enhancer, have good electrical insulation performance, high and low temperature resistance, acid and alkali corrosion resistance, weather resistance and wear resistance, can greatly improve the service life of the insulating connecting body, and can make the branch cable adapt to various laying environments.

[0034] ESO, naphthenic oil and EBS as mixed plasticizer, have lubricity, low temperature resistance and weather resistance, can reduce friction during injection molding, and improve the processing performance and electrical performance of the injection molding material.

[0035] The beneficial effects of the present application are:

[0036] (1) The mobile prefabricated branch cable soft conductor of the present application is dispersed into a peacock tail structure to disperse stress, is fixed by a hoop, and prevents core breakage;

[0037] (2) By coating a hot melt buffer layer on the connecting body, the stress generated by frequent movement of the conductor is borne, and the effect of preventing core breakage is further achieved;

[0038] (3) By using an elastomer material for injection molding insulation of the cable branch, the elastomer injection molding insulation layer can maintain softness at-40℃~90℃, the insulation resistance is >500MΩ after 5 million times of bending, and the dynamic insulation reliability is greatly improved;

[0039] (4) The production process of the mobile prefabricated branch cable is controllable, the red hot melt adhesive tape realizes visual injection molding filling, saves more than 15% of materials, and also realizes waterproofing at the joint between the elastomer connecting insulation layer and the branch cable and the main cable. BRIEF DESCRIPTION OF DRAWINGS

[0040] The present application will be further described below in conjunction with the drawings and examples.

[0041] Figure 1 is a schematic diagram of the internal structure of the present application.

[0042] Figure 2 is a schematic diagram of the structure of the present application.

[0043] Figure 3 is a flow chart of the present application. DETAILED DESCRIPTION

[0044] The present application will now be described in further detail with reference to the drawings. These drawings are simplified schematic diagrams which only show the basic structure of the present application in a schematic manner, and thus only show the components relevant to the present application.

[0045] In the description of the present application, it should be noted that unless explicitly defined and limited otherwise, the terms "connected", "connection" should be interpreted broadly, for example, it can be fixed connection, or detachable connection, or integral connection; it can be mechanical connection, or electrical connection; it can be direct connection, or indirect connection through an intermediate medium. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0046] Figure 1 、 Figure 2 and Figure 3 The structure of the prefabricated branch cable for mobile use shown in the drawings is: from the inside to the outside, the trunk cable 1, the branch cable 2, the connecting body formed by the soft conductor of the trunk cable 1 and the soft conductor of the branch cable 2 and the fixing clamp, the hot melt buffer layer 4, the elastic body insulation fixing layer 5, the injection molding indication layer 6, the transparent polyester film layer 7, and the elastic body injection molding insulation layer 8. The manufacturing process of the prefabricated branch cable for mobile use is as follows:

[0047] S1: stripping the sheath layer and the insulation layer on the trunk cable and the branch cable, exposing the soft conductor of the trunk cable 1 with a length of 5-10 cm, and exposing the soft conductor of the branch cable 2 with a length of 5-10 cm;

[0048] S2: dispersing the soft conductor of the branch cable 2 into a peacock tail shape, and the dispersion width is consistent with the circumference of the soft conductor of the trunk cable 1;

[0049] S3: covering the soft conductor of the branch cable 2 on the soft conductor of the trunk cable 1, spot welding the contact end face, preliminarily fixing, then fixing with a copper clamp to form a connecting body;

[0050] S4 wraps the elastic sheet-shaped hot melt adhesive on the connecting body, heats the hot melt adhesive with a hot melt gun, melts the elastic hot melt adhesive, and tightly covers the circumference of the conductor connection. The width of the elastic sheet-shaped hot melt adhesive is 10mm-20mm, and the covering thickness is 3-5mm. After the elastic hot melt adhesive is completely melted, cold air is blown by a hair dryer for rapid cooling to form an elastic hot melt buffer layer 4. The hot melt buffer layer 4 plays a role of dispersing the stress of the conductor and reinforcing the connecting body;

[0051] S5 nests a tubular insulator on the hot melt buffer layer 4, and uses an oven gun to heat the opening. After the opening is heated, it is melted together to form an elastic body insulation fixing layer 5. The insulator material is consistent with the elastic body injection insulation layer 8;

[0052] S6 wraps 2-3 layers of transparent polyester film layer 7 on the adjacent connecting body, and wraps 2-3 layers of red hot melt adhesive tape as an injection indication layer 6 at the stripped section 3-5cm of the main cable sheath. The width of the wrapped layer is 10-20mm. When the connecting body is injection molded, the injection indication layer 6 melts into a liquid state under high temperature environment, can overflow from the injection mold, can judge in time that the injection material fills the cavity, can save the use of injection material, and can also fill in the joint between the elastic body injection insulation layer 8 and the main cable and branch cable, and play a waterproof role;

[0053] S7 puts the connecting body into the injection mold, extrudes the elastic body injection material on the branch body with an injection molding machine, and forms an elastic body insulation layer with an injection thickness of 3-5cm. The high-temperature injection material can instantly melt the polyester film. The injection material enters the gap of the connecting body, can achieve the effect of balanced injection body, and can prevent the occurrence of injection insulation eccentricity;

[0054] S8 cools the injection body in water for 3-5min, takes it out after cooling, trims the overflow part of the injection insulation, and then puts the connecting body into the cable reel for natural cooling to room temperature.

[0055] The composition of the elastomer injection plastic is: POE polyolefin elastomer accounts for 80% to 85% of the mass, PES polyether sulfone accounts for 1% to 3% of the mass, PVDF polyvinylidene fluoride accounts for 5% to 8% of the mass, ESO epoxy soybean oil accounts for 2% to 5% of the mass, naphthenic oil accounts for 4% to 10% of the mass, EBS ethyl bis stearamide accounts for 0.2% to 0.5% of the mass, antioxidant 1010 accounts for 0.15 to 0.3% of the mass, 1076 accounts for 0.05% to 0.15% of the mass, PES and PVDF are used as corrosion-resistant and insulation performance enhancers, have good electrical insulation performance, high and low temperature resistance, acid and alkali corrosion resistance, weather resistance and wear resistance, can greatly improve the service life of the insulating connecting body, and can make the branch cable adapt to humid, acid and alkali corrosion, seaside saline-alkali corrosion and the like; ESO, naphthenic oil and EBS are used as mixed plasticizers, have lubricity, low temperature resistance and weather resistance, can reduce friction during injection molding, improve the processing performance and electrical performance of the injection plastic, the formula has good waterproof performance, cold resistance, corrosion resistance, weather resistance and insulation performance, and also has the softness of elastomer, and also has excellent processing performance.

[0056] The connecting body of the present application can be in a moving and winding state for a long time, and the conductor is continuously core; the connecting body is soft, and still has good mechanical properties and electrical properties after long-term movement and winding; the connecting body has good waterproof performance, cold resistance, corrosion resistance and weather resistance, and can be applied to various laying occasions.

[0057] Based on the above ideal embodiments according to the present application, through the above description, relevant personnel can make various changes and modifications without deviating from the technical idea of the present application. The technical scope of the present application is not limited to the contents in the specification, and must be determined according to the scope of claims.

Claims

1. A manufacturing process for a prefabricated branch cable for mobile applications, characterized in that, Includes the following steps: S1 strips the sheath and insulation layers of the main cable and branch cables, exposing the soft conductor length of the main cable (1) by 5~10cm and the soft conductor length of the branch cable (2) by 5~10cm. S2 disperses the soft conductor of the branch cable (2) into a peacock tail shape, with the dispersion width matching the perimeter of the soft conductor of the main cable (1); S3 wraps the soft conductor of the branch cable (2) over the soft conductor of the main cable (1), first spot welds it in place and then locks it with a copper clamp; forming a connection between the soft conductor of the main cable and the soft conductor of the branch cable; S4 wraps elastic sheet hot melt adhesive around the connector, heats and melts it, and then cools it quickly to form a hot melt buffer layer (4). S5. A tubular elastomer insulation is placed on the hot melt buffer layer (4), and the opening is heated with a heating gun. The opening is heated and melted together to form a tubular elastomer insulation fixing layer (5). S6 Wrap 2-3 layers of transparent polyester film on multiple adjacent connectors (7), and wrap 2-3 layers of red hot melt adhesive tape with a width of 10-20mm at a distance of 3-5cm from the stripping point of the main cable as an injection molding indicator layer (6). S7 The connector is placed into the injection mold, and the elastomer injection molding material is injected to form an elastomer injection molding insulation layer (8). During the injection process, the injection indicator layer (6) melts and overflows from the mold gap, serving as a visual indicator that the injection filling is complete. After water cooling the S8 for 3-5 minutes, trim off any overflow and allow it to cool naturally to room temperature. The tubular elastomer insulation material in S5 is the same as that of the elastomer injection molding insulation layer (8), and it can also be fused with the elastomer injection molding insulation layer (8) to form an integral insulation.

2. The manufacturing process of a prefabricated branch cable for mobile applications according to claim 1, characterized in that: The injection molding thickness in S7 is 3~5cm and the high-temperature injection molding plastic melts through the transparent polyester film layer (7) to fill the internal gap.

3. The manufacturing process of a prefabricated branch cable for mobile applications according to claim 1, characterized in that: The elastomer injection molding compound used in S7 is composed of the following components by mass percentage: POE polyolefin elastomer 80%~85%, PES polyethersulfone 1%~3%, PVDF polyvinylidene fluoride 5%~8%, ESO epoxidized soybean oil 2%~5%, naphthenic oil 4%~10%, EBS ethyl bis-stearamide 0.2%~0.5%, antioxidant 1010 0.15%~0.3%, and antioxidant 1076 0.05%~0.15%.

4. The manufacturing process of a prefabricated branch cable for mobile applications according to claim 3, characterized in that: PES and PVDF are used as corrosion resistance and insulation enhancers.

5. The manufacturing process of a prefabricated branch cable for mobile applications according to claim 3, characterized in that: ESO, naphthenic oil and EBS were used as a mixed plasticizer.

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