Wire and Cable Lubricating Coating for Lower Pulling Force
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Solution Overview
Problem
Current methods for reducing the coefficient of friction in wires and cables during installation either compromise the chemical, physical, or electrical properties of the materials by mixing or infusing lubricants at high temperatures or are labor-intensive and time-consuming when applied manually.
Innovation Solution
A solvent-free, halogen-free aqueous emulsion composition comprising polytetrafluoroethylene, polyethylene glycol, potassium neutralized vegetable fatty acid, paraffin wax emulsion, polydimethylsiloxane, polyacrylamide polymer, and silicone-based antifoaming agents is applied after the cooling of the insulating material, using a spraying device or submersion in a bath, to reduce friction without affecting the wire or cable's properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If lubricating agents are incorporated into the insulating material during manufacturing at high temperature, then the coefficient of friction is reduced, but the chemical, physical, and electrical properties of the wire or cable are adversely affected
Solution Approach 1:
The lubricating composition is applied to the insulating material surface after manufacturing is complete, rather than during the manufacturing process. This preliminary action (applying lubrication after cooling) avoids exposing the insulating material to high temperatures and chemical mixing that would compromise its properties, while still achieving the desired friction reduction effect before installation begins
Solution Approach 2:
A water-based lubricating composition serves as an intermediary substance that is applied to the surface of the insulating material. This composition acts as a mediator between the installation process and the wire/cable, providing friction reduction without requiring integration into the insulating material itself, thereby preserving the material's inherent properties
2Object-affected harmful factors
If lubricating agents are applied manually by hand at the job site, then the coefficient of friction is reduced, but the installation process becomes time consuming and labor intensive
Solution Approach 1:
The system enables self-service lubrication where the lubricating composition is automatically applied to the wire or cable as it passes through the installation conduit. The composition is delivered through a delivery system that applies lubrication continuously during the pulling operation, eliminating the need for manual application and allowing the installation process to proceed without interruption
Solution Approach 2:
A water-based lubricating composition is used as the lubricating agent, utilizing hydraulic principles for delivery through a pump and hose system. The water-based formulation allows for easy pumping and distribution through the hydraulic delivery system, enabling automated application during the wire or cable installation process without manual intervention
3Object-affected harmful factors
If lubricating agents are mixed or infused into the insulating material, then the coefficient of friction is reduced, but additional materials and mixing processes are required at the job site
Solution Approach 1:
The lubrication function is extracted from the insulating material manufacturing process and separated into a distinct, independent application step. Instead of incorporating lubricants into the insulating material during manufacturing, the lubricating composition is applied separately to the surface of the completed wire or cable, eliminating the need for mixing and infusion processes during installation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively reduces the coefficient of friction and pulling force required during installation, preserving the chemical, physical, and electrical properties of the wire or cable, while being environmentally friendly and applicable to various insulating materials.
Implementation Method 1
The composition comprises lubricating agents that provide lower coefficient of friction for wire or cable installation
Data Source
AI summary
A composition and method for reducing the coefficient of friction and required pulling force of a wire or cable are provided. A composition of aqueous emulsion is provided that is environmentally friendly, halogen free and solvent free. The composition is compatible with various types of insulating materials and may be applied after the wire or cable is cooled and also by spraying or submerging the wire or cable in a bath. The composition contains lubricating agents that provide lower coefficient of friction for wire or cable installation and continuous wire or cable surface lubrication thereafter.