High-Temperature Winding Cable PTFE Fluororubber Structure
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Solution Overview
Problem
Conventional cables made from materials like PVC and TPU are prone to melting, cracking, and combustion when exposed to high temperatures, failing to maintain signal transmission, insulation resistivity, and voltage/current integrity.
Innovation Solution
A high-temperature winding cable is manufactured by winding tinned copper lines with PTFE packaging, followed by thermoplastic and fluororubber extrusion, high-temperature sintering, and baking, which involves winding on an iron bar, baking, cooling, and rewinding to form a durable cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cables use PVC or TPU as insulating materials, then the manufacturing cost is low and processing is easy, but the cable melts and cracks when exposed to high temperatures above 60°C to 105°C
Solution Approach 1:
The patent uses a composite material structure with PTFE as the inner insulating layer and fluororubber as the outer protective layer. PTFE provides exceptional high-temperature resistance (maintaining properties up to 260°C), while fluororubber adds mechanical protection and flexibility. This composite approach resolves the contradiction by achieving superior temperature resistance without sacrificing manufacturability, as both materials are well-established in cable manufacturing.
Solution Approach 2:
The patent changes the material parameters from conventional PVC/TPU to high-temperature resistant PTFE and fluororubber. Specifically, it selects materials with melting points and service temperature ratings suitable for high-temperature environments, thereby transforming the cable's thermal performance parameter from 60-105°C to above 260°C while maintaining manufacturing feasibility.
2Temperature
If the cable is exposed to high temperatures, then the temperature resistance improves, but the cable structure becomes unstable and loses elasticity
Solution Approach 1:
The patent utilizes the phase transition properties of PTFE, which maintains its solid crystalline structure and mechanical properties at temperatures where conventional materials would melt or deform. PTFE's unique phase behavior allows it to retain structural stability and elasticity even when exposed to temperatures above 260°C, preventing the cable from becoming brittle or losing its protective function.
3Temperature
If the cable uses high-temperature resistant materials like PTFE and fluororubber, then the temperature resistance improves, but the manufacturing process complexity increases
Solution Approach 1:
The patent divides the cable structure into distinct segments with specific functions: PTFE inner insulating layer for electrical insulation and high-temperature resistance, fluororubber outer layer for mechanical protection and flexibility, and metal conductors for signal transmission. This segmentation allows each material to be optimized for its specific function while simplifying the overall manufacturing process, as each layer can be applied using standard extrusion techniques.
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
The method produces a cable that resists high temperatures without melting or cracking, retains elasticity, and maintains signal transmission, insulation, and voltage/current integrity for extended periods.
Implementation Method 1
high-temperature sintering: sintering the cable with a temperature ranged from 200° C. to 250° C. for 30 to 45 minutes
Implementation Method 2
baking: placing the cable wound on the iron bar in a baker, and baking it with a temperature ranged from 180° C. ̃200° C. for at least 30 minutes
Implementation Method 3
the cable so made being unable to be melt, not easy to crack and retaining elasticity, and at the same time, still having the normal effects of signal transmission, insulation resistivity and, voltage and current withstanding after the impact of high temperatures
Data Source
AI summary
A method for making a high-temperature winding cable is winding a tinned copper line around a coaxial line, signal lines and power lines after being assembled together, lapping the rim of the tinned copper line with a packaging material of Polytetrafluoroethene, and then, extruding an insulating layer of thermoplastic material on the rim of the packaging material, and finally, extruding an outer cover of fluororubber on the outer rim of the insulating layer, thereby forming a cable; sintering the cable; winding the sintered cable clockwise around and fixing it to a iron bar; cooling the wound cable; and finally, taking down the wound cable from the iron bar by rewinding it counterclockwise so as to obtain a high-temperature winding cable. The winding cable so made is not melt, damaged, and retains elasticity after the impact of high temperature 260° C.