Basalt braided coated teflon skeleton double conductor leak detection line and its braiding method

Abstract

This invention discloses a basalt-braided Teflon-framed dual-conductor leakage detection wire and its braiding method, relating to the technical field of cables. It includes an outer braided layer and at least two mutually insulated conductors. The outer braided layer has a skeleton arranged along its axial direction, and the skeleton has a "Y"-shaped cross-section. At least two branches of the skeleton are respectively covered with an inner braided layer. This basalt-braided Teflon-framed dual-conductor leakage detection wire and its braiding method utilize a polytetrafluoroethylene (PTFE) skeleton with excellent properties such as non-absorption, non-deformation, and resistance to high and low temperatures. It can maintain a constant spacing between the two conductors over a long period, avoiding conductor displacement caused by skeleton deformation due to water absorption. This ensures consistent detection data under different environments and usage periods, effectively reducing false alarms and missed alarms caused by spacing fluctuations. Simultaneously, the skeleton exhibits excellent insulation stability, isolating the conductors from external environmental interference.

Description

Technical Field

[0001] This invention relates to the field of cable technology, specifically to a basalt-braided Teflon skeleton dual-conductor leakage detection wire and its braiding method. Background Technology

[0002] In the field of liquid leak detection, leak detection lines are widely used in computer rooms, pipe corridors, storage tanks and other scenarios. Their detection reliability and service life directly affect the leak early warning effect. Especially in high-risk and high-requirement scenarios such as petrochemical, power computer rooms and urban pipe corridors, once the detection line fails or false alarms, it may cause the leak to spread, equipment damage or even safety accidents, resulting in serious economic losses and safety hazards. Therefore, higher requirements are placed on the environmental adaptability, detection stability and service life of the detection line.

[0003] Existing leak detection lines generally suffer from the following defects: conventional braided layers have poor resistance to high temperatures, aging, and acids and alkalis, and are prone to impedance drift in high temperature and high humidity environments, leading to frequent false alarms; the skeleton material is prone to water absorption and deformation, resulting in unstable conductor spacing and poor detection consistency; it has insufficient tensile strength, bending resistance, and flame retardancy, and is prone to core breakage, short circuits, and failure after long-term use; it has poor reset performance; and its impedance recovers slowly after getting wet, making it impossible to quickly repeat detection.

[0004] Therefore, in view of this, we studied and improved the existing structure and its shortcomings, and proposed a basalt-woven Teflon skeleton double conductor leakage detection wire and its weaving method. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a basalt-woven Teflon skeleton dual-conductor leakage detection wire and its weaving method, thus solving the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a basalt-braided Teflon skeleton dual-conductor leakage detection wire, comprising an outer braided layer and at least two mutually insulated conductors, wherein a skeleton is arranged along the axial direction inside the outer braided layer, and the cross-section of the skeleton is a "Y" shaped structure; the outer sides of at least two branches of the skeleton are respectively covered with inner braided layers, and the conductors are respectively twisted and installed inside the inner braided layers; a filler strip is provided in the gap formed by the "Y" shaped structure of the outer braided layer and the skeleton.

[0007] Furthermore, the conductor is composed of multiple strands of tin-plated copper wire with a diameter of 0.08 mm twisted together, and the conductor's DC resistance is ≤239 Ω. .

[0008] Furthermore, the skeleton is made of polytetrafluoroethylene, and the filler strip is made of aramid fiber.

[0009] Furthermore, the outer braided layer is made of basalt yarn and tightly woven with 8 spindles, and the braiding pitch of the outer braided layer is 10. The rotation speed is controlled at 50±3 rpm.

[0010] A braiding method for a basalt-woven Teflon skeleton dual-conductor leakage detection wire, applied to the basalt-woven Teflon skeleton dual-conductor leakage detection wire, includes the following steps: S1. Conductor stranding: Multiple tinned copper wires with a diameter of 0.08mm are stranded into a conductor, with the single wire tolerance controlled within ±0.003mm, and then the conductor is tinned. S2. Skeleton Preparation: Extrusion molding of a Y-shaped Teflon skeleton, with the core wire inner mold using... 10.4mm, outer mold adopted 9.0mm, ensuring the frame does not absorb water or deform; S3. Perform internal braiding on the outside of the two conductors respectively, using... The yarn, the knitting pitch is controlled at 7±1mm, and the knitting die is... 1.2mm, rotation speed controlled at 43±3 rpm, uniform weaving density; S4. Filling and extrusion: The inner braided conductor and the aramid filler strip are placed together into the Y-shaped groove of the skeleton and the filling and extrusion process is carried out to ensure that the conductor and the skeleton are concentric. S5. Cable Untwisting: A 500-type untwisting machine is used for cable formation. The cable formation direction is S-axis, and the cable pitch is 30±5mm. Only the two inner braided conductors are untwisted; the remaining parts are not untwisted. The untwisting rate is controlled at 85%. The bundling mold is... ; S6. Outer braided layer adopts Basalt yarn is used for external braiding of the cable after cabling, with a braiding pitch of 10±1mm, and the braiding mold is... The rotation speed is 50±3 rpm, and there are no yarn breaks or skips during the weaving process; S7. Testing and Shaping: Verify the finished cable for swaying, insulation resistance, pressure false alarm, and water leakage functions to ensure that the performance meets the standards before shaping and winding.

[0011] Furthermore, in step S3, the weaving machine must be cleaned and degreased before the inner weaving process. The weaving speed must not be adjusted arbitrarily during the weaving process to ensure that the weaving density is uniform and there is no inconsistency in density.

[0012] Furthermore, in step S5, the untwisting machine needs to be adjusted before the cabling process to ensure that the tension of each core is controlled within a certain range. During the untwisting process, avoid conductor deformation caused by fluctuations in cable tension.

[0013] Furthermore, in step S6, the outer braided layer is produced by using two strands of parallel yarn per spindle and eight spindles of yarn. After the braiding is completed, the surface of the cable needs to be inspected to ensure there are no defects such as broken yarns, skipped yarns, or uneven tension.

[0014] Furthermore, in step S7, the swing test conditions are: swing angle ±90°, frequency 30 times / minute, load 50g, and swing count ≥ 5000 times without interruption; the insulation resistance test conditions are: ambient temperature 24℃ and humidity 60%. Insulation resistance > .

[0015] Furthermore, in step S7, the reset performance test requires wiping the outer braided layer of the cable after the water droplet test 3-4 times, and after standing for 3 seconds, the resistance between the two conductors is >300kΩ, so as to achieve rapid reset without residual false alarms.

[0016] This invention provides a basalt-woven Teflon skeleton dual-conductor leakage detection wire and its weaving method, which has the following beneficial effects: 1. The basalt-woven Teflon-backed dual-conductor leakage detection cable and its weaving method. The polytetrafluoroethylene (PTFE) skeleton has excellent properties such as non-absorption of water, non-deformation, and resistance to high and low temperatures. It can maintain a constant spacing between the two conductors for a long time, avoiding conductor displacement caused by skeleton deformation due to water absorption. This ensures consistent detection data in different environments and at different times of use, effectively reducing false alarms and missed alarms caused by spacing fluctuations. At the same time, the skeleton has excellent insulation stability, which can isolate the conductors from external environmental interference, further improving the detection reliability of the cable. It is suitable for various harsh operating scenarios such as high temperature, high humidity, and acid and alkali, and extends the service life of the cable.

[0017] 2. This basalt-braided Teflon-backed dual-conductor leak detection cable and its braiding method utilize a double-layer protection and reinforcement design with aramid filling and basalt braided outer layer. This design balances the cable's mechanical and sensing performance. The aramid filling material significantly improves the cable's tensile strength and flexibility, enabling it to withstand a breaking force exceeding 20KG and over 5000 swing cycles without breaking. This effectively prevents failures such as core breakage and short circuits during long-term use. The basalt braided outer layer not only possesses the characteristics of high temperature resistance, aging resistance, and flame retardancy (VW-1), but its stable surface impedance remains stable and does not slip under high temperature and humidity conditions. As a leak sensing contact surface, it can quickly respond to liquid contact signals. Combined with the dual-conductor structure, it achieves rapid reset. Wiping away water stains 3-4 times and allowing it to stand for 3 seconds restores the standard impedance, enabling repeated detection. It also has excellent protection against pressure, bending, and short-circuit false alarms, making it suitable for long-term use in various scenarios such as computer rooms, pipe racks, and storage tanks. Attached Figure Description

[0018] Figure 1This is a schematic diagram of the structure of a basalt-woven Teflon skeleton dual-conductor leakage detection wire and its weaving method, according to the present invention.

[0019] In the diagram: 1. Outer braided layer; 2. Inner braided layer; 3. Conductor; 4. Skeleton; 5. Filler strip. Detailed Implementation

[0020] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0021] like Figure 1 As shown, the present invention provides a technical solution: a basalt-braided Teflon skeleton dual-conductor leakage detection wire, comprising an outer braided layer 1 and at least two mutually insulated conductors 3. An inner skeleton 4 is arranged along the axial direction inside the outer braided layer 1, and the cross-section of the skeleton 4 is a "Y" shape. The skeleton 4 is made of polytetrafluoroethylene, and the filler strip 5 is made of aramid fiber. At least two branches of the skeleton 4 are respectively covered with inner braided layers 2. The conductors 3 are correspondingly twisted and installed inside each inner braided layer 2. The conductors 3 are composed of multiple tin-plated copper wires with a diameter of 0.08 mm twisted together, and the DC resistance of the conductors 3 is ≤239 Ω. A filling strip 5 is provided in the gap formed by the "Y" shaped structure of the outer braided layer 1 and the skeleton 4.

[0022] A braiding method for a basalt-braided Teflon skeleton dual-conductor leakage detection wire, applied to the basalt-braided Teflon skeleton dual-conductor leakage detection wire, includes the following steps: S1. Conductor stranding: 19 tin-plated copper wires with a diameter of 0.08mm are stranded into conductor 3, with the single wire tolerance controlled within ±0.003mm, and then conductor 3 is tin-plated. S2. Skeleton Preparation: Extruded Y-shaped Teflon skeleton 4, core wire inner mold adopted... 10.4mm, outer mold adopted 9.0mm, ensuring the frame 4 does not absorb water or deform; S3. Internal braiding is performed on the outside of the two conductors 3 respectively, using... The yarn, the knitting pitch is controlled at 7±1mm, and the knitting die is... 1.2mm, the speed is controlled at 43±3 rpm, the weaving density is uniform. In step S3, the weaving machine must be cleaned and degreased before the inner weaving process. The weaving speed should not be adjusted arbitrarily during the weaving process to ensure that the weaving density is uniform and there is no inconsistency in density. S4. Filling and extrusion: The inner braided conductor 3 and the aramid filler strip 5 are placed together into the Y-shaped groove of the skeleton 4 and the filling and extrusion process is carried out to ensure that the conductor 3 and the skeleton 4 are concentric. S5. Cable Untwisting: A 500-type untwisting machine is used for cable formation. The cable formation direction is S-axis, and the cable pitch is 30±5mm. Only the two inner braided conductors are untwisted; the remaining parts are not untwisted. The untwisting rate is controlled at 85%. The bundling mold is... In step S5, the untwisting machine needs to be adjusted before the cabling process to ensure that the tension of each core is controlled within a certain range. During the untwisting process, avoid cable tension fluctuations that could cause conductor 3 to deform; S6. Outer braided layer 1 adopts... Basalt yarn is used for external braiding of the cable after cabling, with a braiding pitch of 10±1mm, and the braiding mold is... The rotation speed is 50±3 rpm. During the weaving process, there are no broken or skipped yarns. In step S6, the outer braided layer 1 is produced using a 2-ply yarn / spindle and 8-spindle braiding method. After weaving, the cable surface must be inspected for any broken yarns, skipped yarns, or uneven tension. S7. Testing and Determination: Verify the finished cable's performance by testing for swing resistance, insulation resistance, false pressure alarms, and water leakage. After ensuring performance meets standards, proceed with shaping and winding. In step S7, the swing test conditions are: swing angle ±90°, frequency 30 times / minute, load 50g, and a swing count ≥5000 times without circuit failure. The insulation resistance test conditions are: ambient temperature 24℃ and humidity 60%. Insulation resistance > In step S7, the reset performance test requires wiping the outer braided layer 1 of the cable after the water droplet test 3-4 times, and after standing for 3 seconds, the resistance between the two conductors 3 is >300kΩ, so as to achieve rapid reset without residual false alarms.

[0023] In summary, as Figure 1 As shown, the basalt-woven Teflon-framed dual-conductor leakage detection wire and its weaving method involve twisting multiple 0.08mm diameter tin-plated copper wires together to form conductor 3, with single-wire tolerance controlled within ±0.003mm, followed by tin plating of conductor 3; subsequently, a Y-shaped Teflon frame 4 is extruded and formed, with the core wire inner mold using... 10.4mm, outer mold adopted 9.0mm, ensuring the skeleton 4 does not absorb water or deform; then, inner braiding is performed, forming the inner braided layer 2 by inner braiding outside the two conductors 3. The yarn, the knitting pitch is controlled at 7±1mm, and the knitting die is... The thickness is 1.2mm, the rotation speed is controlled at 43±3 rpm, the weaving density is uniform, and the weaving machine must be cleaned and degreased before the inner weaving process. The weaving speed should not be adjusted arbitrarily during the weaving process to ensure uniform weaving density and no inconsistency. After the inner weaving is completed, the conductor 3 and the aramid filler strip 5 are placed together into the Y-shaped groove of the skeleton 4 for filling and extrusion process to ensure that the conductor 3 and the skeleton 4 are concentric.

[0024] After filling and extrusion, the cabling and untwisting process is performed using a 500-type untwisting machine. The cabling direction is S-shaped, and the cabling pitch is 30±5mm. Only the two inner braided conductors 3 are untwisted; the remaining parts are not untwisted. The untwisting rate is controlled at 85%. The bundling mold is... The core tension is 2.4mm, and the untwisting machine needs to be adjusted before the cabling process to ensure that the tension of each core is controlled at 0.3±0.15KGF. During the untwisting process, the conductor 3 should not be deformed due to the fluctuation of cable tension. Then, the outer braiding is performed. 3×3tex basalt yarn is used to braid the cable after cabling to form the outer braided layer 1. The braiding pitch is 10±1mm, and the braiding mold is... 3.0mm diameter, rotation speed 50±3 rpm, no yarn breakage or skipping during braiding, and the outer braid uses 2 strands / spindle and 8 spindles for yarn braiding. After braiding, the cable surface must be inspected for defects such as broken yarn, skipping yarn, and uneven tension. Finally, the finished cable is tested for swing, insulation resistance, pressure false alarm, and water leakage to ensure performance meets the standards before shaping and winding. The swing test conditions are swing angle ±90°, frequency 30 times / minute, load 50g, swing times ≥5000 times without circuit failure. The insulation resistance test conditions are ambient temperature 24℃, humidity 60%RH, insulation resistance > For the reset performance test, the outer braided layer 1 of the cable after the water droplet test needs to be wiped 3-4 times. After standing for 3 seconds, the resistance between the two conductors 3 should be greater than 1. To achieve rapid reset and eliminate false alarms, the inner braided layer 2 wraps around the single conductor 3, providing auxiliary insulation and shaping to prevent the conductor 3 from loosening and to isolate the filler strip 5 from direct contact with the conductor 3, thus avoiding interference with the impedance of the conductor 3. The outer braided layer 1, made of tightly woven basalt yarn, serves as the direct sensing contact surface for liquid leaks. Its surface has stable impedance characteristics and moderate hydrophilicity. When liquids such as water, oil, or acid / alkali solutions leak and come into contact with the outer braided layer 1, the liquid, as a conductive medium, will penetrate between the outer braided layer 1 and the inner braided layer 2, thus forming a weak conductive path between the two conductors 3. This causes the impedance value between the two conductors 3 to drop rapidly. When the impedance value is lower than a preset threshold, the connected detection device will trigger a leak alarm signal, achieving accurate leak identification. After the leaked liquid is removed, the basalt yarn outer braided layer 1 has good hydrophobic properties. After wiping 3-4 times and letting it stand for 3 seconds, the residual liquid on the surface can evaporate quickly, the conductive path between the two conductors 3 disappears, and the impedance value returns to normal. This allows for rapid reset, enabling immediate re-testing and meeting the needs of repeated testing. Throughout the entire working process and braiding, the non-absorbent and non-deformable properties of the Teflon skeleton 4 ensure that the spacing between the conductors 3 remains stable, avoiding impedance drift caused by spacing changes. The stable surface impedance of the basalt braided outer layer 1 prevents false alarms in high-temperature and high-humidity environments. The reinforcing effect of the aramid filler strip 5 ensures long-term stable operation of the cable under complex working conditions, while the auxiliary insulation and shaping function of the inner braided layer 2 further enhances testing stability.

[0025] The embodiments of the present invention are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the invention to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described in order to better illustrate the principles and practical application of the invention, and to enable those skilled in the art to understand the invention and to design various embodiments with various modifications suitable for a particular purpose.

Claims

1. A basalt-braided Teflon skeleton dual-conductor leakage detection wire, comprising an outer braided layer (1) and at least two mutually insulated conductors (3), characterized in that: The outer braided layer (1) has a skeleton (4) arranged along the axial direction inside, and the cross-section of the skeleton (4) is a "Y" shaped structure; the outer sides of at least two branches of the skeleton (4) are respectively covered with inner braided layers (2), and the conductors (3) are respectively twisted and installed inside each inner braided layer (2); a filler strip (5) is arranged in the gap formed by the "Y" shaped structure of the outer braided layer (1) and the skeleton (4).

2. The basalt-woven Teflon-framed dual-conductor leakage detection wire according to claim 1, characterized in that: The conductor (3) is made of multiple strands of tin-plated copper wire with a diameter of 0.08 mm, and the DC resistance of the conductor (3) is ≤239 Ω. .

3. The basalt-woven Teflon-framed dual-conductor leakage detection wire according to claim 1, characterized in that: The skeleton (4) is made of polytetrafluoroethylene, and the filler strip (5) is made of aramid fiber.

4. The basalt-woven Teflon-framed dual-conductor leakage detection wire according to claim 1, characterized in that: The outer braided layer (1) is made of basalt yarn and tightly woven with 8 spindles, and the braiding pitch of the outer braided layer (1) is 10. The rotation speed is controlled at 50±3 rpm.

5. A method for weaving a basalt-braided Teflon skeleton dual-conductor leakage detection wire, applied to the basalt-braided Teflon skeleton dual-conductor leakage detection wire according to any one of claims 1-4, characterized in that: The braiding method for the basalt-woven Teflon-framed dual-conductor leak detection wire includes the following steps: S1. Conductor stranding: Multiple tin-plated copper wires with a diameter of 0.08mm are stranded into a conductor (3), with the single wire tolerance controlled within ±0.003mm, and then the conductor (3) is tin-plated. S2. Skeleton preparation: Y-shaped Teflon skeleton (4) is extruded and molded, and the inner mold of the core wire is adopted. 10.4mm, outer mold adopted 9.0mm, ensuring that the frame (4) does not absorb water or deform; S3. Inner braiding is performed on the outside of the two conductors (3), using... The yarn, the knitting pitch is controlled at 7±1mm, and the knitting die is... 1.2mm, rotation speed controlled at 43±3 rpm, uniform weaving density; S4. Filling and extrusion: The inner braided conductor (3) and the aramid filler strip (5) are placed together into the Y-shaped groove of the skeleton (4) and the filling and extrusion process is carried out to ensure that the conductor (3) and the skeleton (4) are concentric. S5. Cable untwisting: A 500-type untwisting machine is used for cable formation. The cable formation direction is S-direction, and the cable pitch is 30±5mm. Only the two inner braided conductors (3) are untwisted, and the rest are not untwisted. The untwisting rate is controlled at 85%. The wire-splitting mold is... ; S6. Outer braided layer (1) adopts Basalt yarn is used for external braiding of the cable after cabling, with a braiding pitch of 10±1mm, and the braiding mold is... The rotation speed is 50±3 rpm, and there are no yarn breaks or skips during the weaving process; S7. Testing and Shaping: Verify the finished cable for swaying, insulation resistance, pressure false alarm, and water leakage functions to ensure that the performance meets the standards before shaping and winding.

6. The braiding method of a basalt-woven Teflon skeleton dual-conductor leakage detection wire according to claim 5, characterized in that: In step S3, the weaving machine must be cleaned and degreased before the inner weaving process. The weaving speed must not be adjusted arbitrarily during the weaving process to ensure that the weaving density is uniform and there is no inconsistency in density.

7. The braiding method of a basalt-woven Teflon skeleton dual-conductor leakage detection wire according to claim 6, characterized in that: In step S5, the untwisting machine needs to be adjusted before the cabling process to ensure that the tension of each core is controlled within the specified range. During the untwisting process, avoid cable tension fluctuations that could cause conductor (3) deformation.

8. The braiding method of a basalt-woven Teflon skeleton dual-conductor leakage detection wire according to claim 5, characterized in that: In step S6, the outer braided layer (1) is produced by using 2 strands / spindle of parallel yarn and 8 spindles of braided yarn. After the braiding is completed, the surface of the cable needs to be checked to ensure there are no broken yarns, skipped yarns, or uneven tension.

9. The braiding method of a basalt-woven Teflon skeleton dual-conductor leakage detection wire according to claim 8, characterized in that: In step S7, the swing test conditions are: swing angle ±90°, frequency 30 times / minute, load 50g, and swing count ≥ 5000 times without interruption. The insulation resistance test conditions are: ambient temperature 24℃ and humidity 60%. Insulation resistance > .

10. The braiding method of a basalt-woven Teflon skeleton dual-conductor leakage detection wire according to claim 9, characterized in that: In step S7, the reset performance test requires wiping the outer braided layer (1) of the cable after the water drop test 3-4 times, and after standing for 3 seconds, the resistance between the two conductors (3) is >300kΩ, so as to achieve rapid reset without residual false alarm.

Images