Bent wire with long bending life and processing method thereof

Abstract

The invention discloses a bending wire with long bending life and a processing method thereof, and the wire comprises a plurality of wires, and each wire comprises an insulating layer, a guide wire bundle and a core wire which are arranged from outside to inside; the filling wires are arranged among the wires; the conducting wires and the filling wires are arranged on the inner side of the isolating layer; the sheath layer is arranged on the outer side of the isolation layer, and the processing method comprises the steps of S1, conductor manufacturing; s2, insulating treatment; s3, cabling processing is carried out; and S4, sheath forming. Through the improvement, the bending service life of the wire rod is prolonged, the bending times of the wire rod can greatly exceed that of a common wire rod, good structural stability and conductive performance are always kept in the multi-bending process, the strict requirements of high-end electronic equipment and the like for the high bending performance of the wire rod are fully met, and the reliability and durability of the wire rod are improved.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and particularly to bending cables and their processing methods. Background Technology

[0002] In the field of electronic device connectivity, flexible cables are widely used, such as in foldable electronic devices and internal wiring for robots, where cables require frequent bending. However, existing ordinary flexible cables have a relatively low bending lifespan, typically only able to withstand around 180 degrees / 15,000 bends. With the continuous expansion of electronic device functions and the diversification of usage scenarios, customers are demanding higher bending lifespans from cables, such as requiring them to withstand 150,000 bends. Due to limitations in their conductor structure, annealing processes, and overall cable design, existing ordinary cables struggle to meet these growing demands for high bending lifespans, severely hindering performance improvements and user experience in related electronic devices. Summary of the Invention

[0003] The purpose of this invention is to provide a bending wire with a high bending life, which can solve the problem of low bending life of wires.

[0004] The present invention also provides a processing method for the above-mentioned bent wire.

[0005] According to a first aspect of the present invention, a high bending life bending wire is provided, comprising: a plurality of conductors, each conductor including an insulation layer, a guide wire bundle, and a core wire disposed from the outside in; a filler wire disposed between the conductors; an isolation layer, the conductors and the filler wire disposed inside the isolation layer; and a sheath layer disposed outside the isolation layer.

[0006] According to the high bending life bending wire, the insulation layer material is EPDM.

[0007] According to the high bending life bending wire, the core wire material is aramid.

[0008] According to the high bending life bending wire, the filler wire material is polyester.

[0009] According to the high bending life bending wire, the insulating layer is made of non-woven fabric.

[0010] According to the high bending life bending wire, the sheath material is CPE.

[0011] According to a first aspect of the present invention, a method for processing the above-mentioned high bending life bent wire is provided, comprising: S1, Conductor Manufacturing: The multiple conductor wires that make up the guide wire bundle are drawn and annealed online, forming a single conductor wire with a diameter of 0.12-0.19 mm and a drawing speed of 22-25 m / s; the conductor wires are annealed at 300-330℃ for 4.5-5.5 h, and then slowly cooled to 48-53℃ to eliminate work hardening; the guide wire bundle is formed and an aramid core wire is implanted in the center of the guide wire bundle; S2. Insulation treatment: The wire bundle is passed through an insulating powder and dried at 55-65℃; a high-elasticity EPDM blend is extruded onto the surface of the wire bundle to form an insulating layer, thereby manufacturing a wire. The high-elasticity EPDM blend extrusion temperature is 130-140℃, and the insulation layer wall thickness is 0.75-1mm. S3, Cable processing: The conductors undergo untwisting and stranding processing with a 100% untwisting rate and a strand pitch of *OD; polyester filler wire is inserted between every two conductors with a filler density of not less than 80%. S4, Sheath Forming: A non-woven fabric insulating layer is longitudinally wrapped around the conductor and filler wire; a high-elasticity CPE composite adhesive is extruded onto the surface of the insulating layer to form a sheath layer. The extrusion temperature of the high-elasticity CPE composite adhesive is 120-130℃, and the wall thickness of the insulation layer is 0.75-1mm.

[0012] According to the processing method of the high bending life bending wire, in the step of forming a guide wire bundle and inserting an aramid core wire into the center of the guide wire bundle, the core wire is pre-tensioned to 1.5-2.5N and then simultaneously twisted with multiple conductor wires to form a guide wire bundle and insert the core wire into the center of the guide wire bundle.

[0013] According to the processing method of the high bending life bending wire, in the step of slowly cooling the conductor wire to 48-53°C to eliminate work hardening, the ambient temperature of the slow cooling environment is controlled to be continuous or gradually decreased so that the slow cooling time of the conductor wire is 1.8-2 times that of the direct cooling time at room temperature.

[0014] The above scheme has the following beneficial effects: 1. High bending life of the wire: Through the above improvements, the bending life of the wire developed in this invention is improved. Tests have shown that it can significantly exceed the number of bends of ordinary wires, which can fully meet the stringent requirements of high-end electronic equipment for high bending performance of wires, and improve the reliability and durability of the wire. 2. Stable wire performance: The addition of aramid core filaments and copper wire annealing process in the wire bundle ensures that the wire bundle maintains good structural stability and conductivity during multiple bending processes; the protection of the insulation layer by filler materials such as polyester ensures that the electrical insulation performance of the wire does not decrease during long-term bending and use, thus guaranteeing the overall stability of the wire performance.

[0015] 3. Wide applicability of the wire: The high bending life and stable performance of the wire of this invention make it suitable for more complex and demanding application scenarios, such as the connection wire of flexible display screens that require frequent folding, and the connection wire inside precision instruments that requires frequent bending, thus broadening the application range of the wire and providing support for the innovative design of electronic devices.

[0016] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0017] The present invention will be further described below with reference to the accompanying drawings and embodiments; Figure 1 This is a schematic cross-sectional view of the high bending life bending wire of the present invention; Figure 2 This is a flowchart illustrating the processing method of the high bending life of the bent wire of the present invention. Detailed Implementation

[0018] This section will describe in detail specific embodiments of the present invention. Preferred embodiments of the present invention are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and overall technical solution of the present invention, but they should not be construed as limiting the scope of protection of the present invention.

[0019] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0020] Reference Figure 1 This invention discloses a high-bending-life bending wire, comprising conductors 10, filler wires 20, an insulating layer 30, and a sheath layer 40. Multiple conductors 10 are provided, each including an insulating layer 11, a guide wire bundle 12, and a core wire 13 arranged from the outside in. The filler wires 20 are disposed between adjacent conductors 10, and the conductors 10 and filler wires 20 are disposed inside the insulating layer 30. The sheath layer 40 is disposed outside the insulating layer 30. The guide wire bundle 12 is made of copper, the insulating layer 11 is made of EPDM, the core wire 13 is made of aramid, the filler wires 20 are made of polyester, the insulating layer 30 is made of non-woven fabric, and the sheath layer 40 is made of CPE.

[0021] As described above, the three-stage mechanical decomposition system—13% energy absorption from the aramid core yarn, 20% force component from the polyester filler yarn, and 30% buffering from the non-woven fabric isolation layer—combined with the ultra-high elasticity of EPDM and CPE, improves the bending life limit of cables for consumer electronics and power tools. These cables maintain conductivity and structural integrity even after numerous bends, meeting the requirements of high-frequency bending scenarios such as wearable devices and power tools.

[0022] Reference Figure 2 The present invention provides a method for processing bent wires with high bending life, comprising the following steps: S1, Conductor Manufacturing: The multiple conductor wires constituting the guide wire bundle 12 are drawn and annealed online. The diameter of the single conductor wire is 0.12-0.19 mm, the drawing speed is 22-25 m / s, and the online annealing current is 450-550 A. The conductor wires are annealed at 300-330℃ for 4.5-5.5 h, and then the conductor wires are slowly cooled to 48-53℃ to eliminate work hardening. The guide wire bundle 12 is formed and an aramid core wire 13 is implanted in the center of the guide wire bundle 12. S2. Insulation treatment: The wire bundle 12 is passed through the isolation powder and dried at 55-65℃. A high-elasticity EPDM blend is extruded onto the surface of the wire bundle 12 to form an insulating layer 11, thereby manufacturing a wire 10. The high-elasticity EPDM blend extrusion temperature is 130-140℃, and the wall thickness of the insulating layer 11 is 0.75-1mm. S3, Cable processing: The conductor 10 is subjected to untwisting stranding with a untwisting rate of 100% and a strand pitch of (15-18)*OD; polyester filler wire 20 is filled between every two conductors 10 with a filler density of not less than 80%; S4, Sheath Forming: A non-woven fabric insulating layer 30 is longitudinally wrapped around the conductor 10 and the filler wire 20; a high-elasticity CPE composite adhesive is extruded onto the surface of the insulating layer 30 to form a sheath layer 40. The extrusion temperature of the high-elasticity CPE composite adhesive is 120-130℃, and the wall thickness of the insulation layer 11 is 0.75-1mm.

[0023] In the step of forming the guide wire bundle 12 and inserting the aramid core wire 13 into the center of the guide wire bundle 12, the core wire 13 is pre-tensioned to 1.5-2.5N and then simultaneously twisted with multiple conductor wires to form the guide wire bundle 12 and to insert the core wire 13 into the center of the guide wire bundle 12.

[0024] In the step of slowly cooling the conductor wire to 48-53℃ to eliminate work hardening, the ambient temperature of the slow cooling environment is controlled to be continuously or gradually decreased so that the slow cooling time of the conductor wire is 1.8-2 times the direct cooling time at room temperature (usually calibrated at 25℃). Specifically, in the slow cooling step, the initial slow cooling ambient temperature is not higher than 50% of the annealing temperature. When the temperature is continuously reduced, the temperature and time have a linear relationship. When the temperature is gradually reduced, the temperature difference between adjacent stages is not greater than 30℃.

[0025] In one embodiment, the processing method may be as follows: S1, Conductor manufacturing process

[0026] S2, Insulation treatment process

[0027] S3, Cable forming process

[0028] Among them, the high-temperature resistant polyester yarn needs to be centered during filling to prevent the cotton yarn from jumping out of the strands, which would cause the appearance to crack when the sheath is extruded.

[0029] S4, Sheath forming process

[0030] In the above scheme, the improvement of the bending life of the cable adopts a three-level progressive approach: "conductor ultra-flexibility → layered stress decomposition → high-elasticity full coverage". Specifically: the conductor is made of ultra-fine alloy + aramid fiber to achieve no short circuit after a large number of bends; the cabling is made of untwisted stranding + high-temperature polyester filling to disperse bending stress in a secondary way; the sheath is made of longitudinally wrapped non-woven fabric + high-elastic rubber to achieve three-level protection and maintain roundness.

[0031] In this invention, aramid fiber is added to the wire bundle. Aramid fiber possesses high strength, high modulus, and good flexibility. Adding it to the wire bundle significantly improves the tensile and bending resistance of the wire without affecting its conductivity. Using the aforementioned annealing process parameters ensures the copper wire reaches a good crystalline state during annealing, thereby increasing the flexibility of the wire bundle and reducing stress concentration within the wire bundle during bending. Adding filler materials such as polyester to the wire structure provides excellent elasticity and cushioning properties. When the wire is bent, it effectively protects the insulation layer, preventing damage and cracking, thus ensuring the electrical performance and service life of the wire.

[0032] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A high-bending life bending wire, characterized by, The utility model relates to a kind of cable, including: Multiple wires (10), the wire (10) includes from outside to inside arranged insulating layer (11), wire bundle (12) and core wire (13); Filler wire (20), the filler wire (20) is arranged between wire (10); Insulation layer (30), the wire (10) and filler wire (20) are arranged inside insulation layer (30); Sheath layer (40), the sheath layer (40) is arranged outside insulation layer (30).

2. The high-bend life bending wire of claim 1, wherein, The insulating layer (11) material is EPDM.

3. The high-bend life bending wire of claim 2, wherein, The core wire (13) material is aramid.

4. The high-bend life bending wire of claim 3, wherein, The filler wire (20) material is polyester.

5. The high-bend life bending wire of claim 4, wherein, The insulation layer (30) material is non-woven fabric.

6. The high-bend life bending wire of claim 5, wherein, The sheath layer (40) material is CPE.

7. The method of claim 6, wherein the bending wire has a bending life of 100,000 cycles or more. Including: S1, conductor manufacturing: Wire drawing and on-line annealing are carried out on the plurality of conductor filaments constituting the wire bundle (12), the single filament diameter of the conductor filament is 0.12-0.19 mm, and the drawing speed is 22-25 m / s; Secondary annealing treatment is carried out on the conductor filament at 300-330 DEG C for 4.5-5.5 h, and the conductor filament is slowly cooled to 48-53 DEG C to eliminate work hardening; the wire bundle (12) is formed, and the core wire (13) made of aramid is implanted in the center of the wire bundle (12); S2, insulation treatment: The wire bundle (12) passes through the isolation powder, and the wire bundle (12) is dried in an environment of 55-65 DEG C; high-elasticity EPDM is blended and extruded on the surface of the wire bundle (12) to form an insulating layer (11), thereby manufacturing a wire (10), the high-elasticity EPDM blending and extrusion temperature is 130-140 DEG C, and the insulating layer (11) wall thickness is 0.75-1 mm; S3, cable processing: The wire (10) is subjected to untwisting and twisting processing, the untwisting rate is 100%, and the lay length is (15-18)*OD; the filler wire (20) made of polyester is filled between every two wires (10), and the filling density is not less than 80%; S4, sheath forming: The insulation layer (30) made of non-woven fabric is longitudinally wrapped outside the wire (10) and the filler wire (20); the high-elasticity CPE composite adhesive is extruded on the surface of the insulation layer (30) to form a sheath layer (40), the high-elasticity CPE composite adhesive extrusion temperature is 120-130 DEG C, and the insulating layer (11) wall thickness is 0.75-1 mm.

8. The method of claim 7, wherein the high-bend life bending wire is made of a material having a hardness of 45 to 55 HRC. In the step of forming the wire bundle (12) and implanting the core wire (13) made of aramid in the center of the wire bundle (12), the core wire (13) is pre-tensioned at 1.5-2.5 N and then twisted synchronously with the plurality of conductor filaments, so as to form the wire bundle (12) and implant the core wire (13) in the center of the wire bundle (12).

9. The method of claim 7, wherein the high-bend life bending wire is made of a material having a hardness of 45 to 55 HRC. In the step of slowly cooling the conductor filament to 48-53 DEG C to eliminate work hardening, the slow cooling environment temperature is continuously controlled or gradually decreased, so that the slow cooling time of the conductor filament is 1.8-2 times of the direct cooling time at room temperature.

Images