CN101685684B - Copper-clad aluminum flexible cable and manufacturing method thereof - Google Patents
Copper-clad aluminum flexible cable and manufacturing method thereof Download PDFInfo
- Publication number
- CN101685684B CN101685684B CN2008101668698A CN200810166869A CN101685684B CN 101685684 B CN101685684 B CN 101685684B CN 2008101668698 A CN2008101668698 A CN 2008101668698A CN 200810166869 A CN200810166869 A CN 200810166869A CN 101685684 B CN101685684 B CN 101685684B
- Authority
- CN
- China
- Prior art keywords
- copper
- cable
- wire
- core
- conductive
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 135
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 133
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 31
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims abstract description 76
- 239000003063 flame retardant Substances 0.000 claims abstract description 76
- 238000009413 insulation Methods 0.000 claims abstract description 68
- 229910052802 copper Inorganic materials 0.000 claims abstract description 67
- 239000010949 copper Substances 0.000 claims abstract description 67
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 62
- 238000000034 method Methods 0.000 claims abstract description 38
- 238000000137 annealing Methods 0.000 claims abstract description 27
- 238000012545 processing Methods 0.000 claims abstract description 23
- 229920003023 plastic Polymers 0.000 claims abstract description 13
- 239000004033 plastic Substances 0.000 claims abstract description 13
- 239000004020 conductor Substances 0.000 claims description 34
- 238000002955 isolation Methods 0.000 claims description 33
- 238000005253 cladding Methods 0.000 claims description 19
- 230000009970 fire resistant effect Effects 0.000 claims description 18
- 230000008569 process Effects 0.000 claims description 13
- 238000011049 filling Methods 0.000 claims description 10
- 238000004804 winding Methods 0.000 claims description 5
- 239000000463 material Substances 0.000 description 10
- 239000010445 mica Substances 0.000 description 9
- 229910052618 mica group Inorganic materials 0.000 description 9
- 238000004891 communication Methods 0.000 description 6
- 238000010586 diagram Methods 0.000 description 6
- 239000004745 nonwoven fabric Substances 0.000 description 6
- 229920000098 polyolefin Polymers 0.000 description 6
- 229920000915 polyvinyl chloride Polymers 0.000 description 6
- 239000004800 polyvinyl chloride Substances 0.000 description 6
- 239000000779 smoke Substances 0.000 description 6
- 150000001879 copper Chemical class 0.000 description 5
- 239000003365 glass fiber Substances 0.000 description 5
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 230000004888 barrier function Effects 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 230000002194 synthesizing effect Effects 0.000 description 2
- 241001391944 Commicarpus scandens Species 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 230000008054 signal transmission Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
Images
Landscapes
- Insulated Conductors (AREA)
Abstract
The invention discloses a copper-clad aluminum two-core flame-retardant flexible cable and a manufacturing method thereof, wherein the method comprises the following steps: a step of manufacturing the copper-clad aluminum wire into a single conductive wire core; processing the single conductive wire core into a conductive wire core with a semicircular cross section; an insulation processing step of performing insulation processing on the conductive wire core with the semicircular cross section to form an insulation wire core with an insulation layer; cabling two insulated wire cores with insulating layers to form a cable; and extruding plastic on the cable to form a flame-retardant sheath layer. Wherein the step of making the copper-clad aluminum wire into a single conductive wire core comprises the following steps: drawing the copper-clad aluminum wire into a single conductive monofilament by using a drawing machine; annealing the single conductive monofilament by using an annealing machine; using a yarn bundling machine to bundle a plurality of annealed conductive monofilaments into folded yarns; and stranding a plurality of the folded yarns into the conductive wire core by using a stranding machine. The cable of the invention has the advantages of less copper, light weight and low cost.
Description
Technical Field
The invention relates to the wire and cable technology, in particular to a copper-clad aluminum flexible cable and a manufacturing method thereof.
Background
Regarding the concept of copper-clad aluminum, wire and cable manufacturers are not strange, namely, the structure of each conductive monofilament forming a conductive wire core is processed into outer copper and inner aluminum, so that not only can a large amount of copper belonging to strategic resources be saved, but also the copper can play the greatest role. There have been no reports in the literature, such as chinese patent literature, for example: the copper-clad aluminum urban communication cable introduced in chinese patent publication No. CN2881898, the copper-clad aluminum data communication cable disclosed in CN2881899, the copper-clad aluminum communication cable recommended by CN200979818Y, the copper-clad aluminum conductor or copper-clad steel conductor electric cable disclosed in CN101060024A, the bimetallic conductor monitoring type grounding cable disclosed in CN2829026Y, a high-strength copper-clad aluminum electric wire/cable disclosed in CN2906844Y, and the like CN1758384Y, CN201004349Y, CN2919466Y, CN101086906Y, CN200986831Y, CN2348466Y, CN2904222Y, CN200976298Y, CN200969249Y, CN2891231Y, CN2879357Y and the like all relate to cladding aluminum conductors with copper cladding, and the purpose is to save copper resources.
However, the aluminum material has small tension and low strength, so that the copper-clad aluminum conductor is easy to break and the processing difficulty is obviously increased for the copper-clad aluminum conductor with small diameter or copper consumption, and even the copper-clad aluminum conductor cannot be processed at all. And if the diameter is enlarged or the copper amount is increased, the cable is hard and is not beneficial to laying.
Disclosure of Invention
The invention aims to provide a copper-clad aluminum flexible cable which has excellent flexibility, is favorable for laying, is easy to process and is safe to use, and a manufacturing method thereof.
According to one aspect of the invention, the manufacturing method of the copper-clad aluminum flexible cable comprises the following steps:
a step of manufacturing a copper-clad aluminum wire into a single conductive wire core, wherein copper accounts for 15% -30% of the volume of the copper-clad aluminum wire;
an insulation processing step of performing insulation processing on the single conductive wire core to form an insulation wire core with an insulation layer;
cabling treatment is carried out on one or more insulating wire cores with insulating layers to form a cable; and
and extruding plastic on the cable to form a flame-retardant sheath layer.
Wherein the cabling process comprises:
stranding the plurality of insulation wire cores and the filling rope by using a cabling machine to form a round wire harness;
and then, winding a cable isolation layer on the round wire harness to form the cable.
According to another aspect of the invention, the manufacturing method of the copper-clad aluminum flexible cable comprises the following steps:
a step of manufacturing the copper-clad aluminum wire into a single conductive wire core, wherein copper accounts for 15% -30% of the volume of the copper-clad aluminum wire;
processing the single conductive wire core into a conductive wire core with a semicircular or fan-shaped or tile-shaped cross section;
an insulation processing step of performing insulation processing on the conductive wire core with the semicircular or fan-shaped or tile-shaped cross section to form an insulation wire core with an insulation layer;
cabling treatment is carried out on one or more insulating wire cores with insulating layers to form a cable; and
and extruding plastic on the cable to form a flame-retardant sheath layer.
Wherein the cabling treatment comprises the following steps:
stranding a plurality of insulated wire cores with semicircular or fan-shaped or tile-shaped cross sections by using a cabling machine to form a wire harness;
and then, winding a cable isolation layer on the wire harness to form the cable.
The method comprises the following steps of preparing a copper-clad aluminum wire into a single conductive wire core:
drawing the copper-clad aluminum wire into a single conductive monofilament by using a drawing machine;
annealing the single conductive monofilament by using an annealing machine;
using a yarn bundling machine to bundle a plurality of annealed conductive monofilaments into folded yarns;
and stranding a plurality of the folded yarns into the conductive wire core by using a stranding machine.
For the copper clad aluminum flame-retardant flexible cable, the core isolation layer can be a non-woven fabric isolation layer, and the cable isolation layer can be a non-woven fabric isolation layer.
For the copper-clad aluminum flame-retardant and fire-resistant flexible cable, the core isolation layer can be a core fire-resistant layer and comprises a mica layer wrapped on the outer surface of the single conductive core and a glass fiber layer wrapped on the outer surface of the mica layer; the cable insulation layer may be a cable flame retardant layer.
Wherein the drawing angle for drawing the copper-clad aluminum wire into a single conductive monofilament is 12-14 degrees; the annealing temperature in the annealing treatment is controlled to be 540 +/-10 ℃.
According to still another aspect of the present invention, a copper-clad aluminum flexible cable manufactured according to the method of the present invention comprises:
a conductive core having an insulating layer, the conductive core having a circular cross-section;
the cable isolation layer wraps one or more conductive wire cores with insulation layers; and
the flame-retardant sheath layer is extruded on the cable isolation layer; wherein:
the conductive wire core is formed by twisting a plurality of strands of conductive monofilaments;
the conductive monofilament consists of an aluminum conductor and a copper cladding coated outside the aluminum conductor, wherein the copper cladding accounts for 15% -30% of the volume of the conductive monofilament, and the aluminum conductor accounts for 85% -70% of the volume of the conductive monofilament.
According to still another aspect of the present invention, a copper-clad aluminum flexible cable manufactured according to the method of the present invention comprises:
the conductive wire core is provided with an insulating layer, and the cross section of the conductive wire core is semicircular, fan-shaped or tile-shaped;
the cable isolation layer wraps one or more conductive wire cores with insulation layers; and
the flame-retardant sheath layer is extruded on the cable isolation layer 4; wherein:
the conductive wire core is formed by twisting a plurality of strands of conductive monofilaments;
the conductive monofilament consists of an aluminum conductor and a copper cladding coated outside the aluminum conductor, wherein the copper cladding accounts for 15% -30% of the volume of the conductive monofilament, and the aluminum conductor accounts for 85% -70% of the volume of the conductive monofilament.
The diameter of the conductive monofilament is 0.2-1.2 mm, the diameter of the aluminum conductor is 0.18439-1.10635 mm, and the thickness of the copper cladding is 0.007805-0.04685 mm.
In addition, the copper-clad aluminum flexible cable further comprises a filling rope filled between the cable isolating layer and the insulating layer.
Wherein, the insulating layer can be flame-retardant polyvinyl chloride or low-smoke halogen-free polyolefin material insulating layer; the sheath layer can be made of flame-retardant polyvinyl chloride or low-smoke halogen-free polyolefin material.
The invention has the following technical effects: less copper, light weight and low cost. Because of the adoption of a monofilament structure with a plurality of small diameters and a multi-strand stranding process, the cable is particularly flexible and can be bent randomly.
The present invention will be described in detail with reference to the accompanying drawings.
Drawings
FIG. 1 is a schematic diagram showing the structure of a copper-clad aluminum two-core round flame-retardant flexible cable of the invention;
FIG. 2 is a schematic diagram showing the structure of a copper-clad aluminum two-core semicircular flame-retardant flexible cable of the invention;
fig. 3 is a schematic view showing the structure of the conductive monofilament 11 of the present invention;
FIG. 4 is a schematic diagram showing the structure of a copper clad aluminum three-core round flame-retardant flexible cable of the invention;
FIG. 5 is a schematic view showing the structure of a copper clad aluminum three-core fan-shaped flame-retardant flexible cable of the present invention;
FIG. 6 is a schematic view showing the structure of a copper clad aluminum four-core round flame-retardant flexible cable of the present invention;
FIG. 7 is a schematic view showing the structure of a copper clad aluminum four-core fan-shaped flame-retardant flexible cable of the present invention;
FIG. 8 is a schematic view showing the structure of a copper clad aluminum five-core round flame-retardant flexible cable of the invention;
FIG. 9 is a schematic diagram showing the structure of the copper-clad aluminum five-core tile-shaped flame-retardant flexible cable of the invention.
FIG. 10 is a schematic view showing the structure of a copper-clad aluminum two-core round flame-retardant fire-resistant flexible cable of the present invention;
FIG. 11 is a schematic diagram showing the structure of the copper-clad aluminum two-core semicircular flame-retardant fire-resistant flexible cable of the invention.
Detailed Description
The invention adopts the copper-clad aluminum conductor core 1 with the copper content of 15-30% to manufacture the flexible cable, and the copper-clad aluminum conductor core 1 with the copper content of 15-30% not only can greatly reduce the manufacturing cost, but also can ensure the communication quality because the copper clad of the copper-clad aluminum wire or the copper-clad aluminum wire core can be utilized to effectively transmit communication signals. Experiments show that when the copper content of a copper-clad layer in a copper-clad aluminum wire or a copper-clad aluminum conductive wire core is 15% -30% (namely the copper occupies 15% -30% of the volume of the conductive wire or the wire core), the signal transmission efficiency of the conductive wire is basically equal to the efficiency of the copper conductive wire core with the same diameter.
The "copper content" in the present invention means: the copper or the copper clad layer occupies the volume percentage of the copper clad aluminum wire or the copper clad aluminum conductive wire core, or the volume percentage of the copper or the copper clad layer. For example, a copper content of 15% means that the copper or copper cladding occupies 15% of the volume of the copper clad aluminum wire or copper clad aluminum conductive wire core (85% of the volume of aluminum).
For the copper-clad aluminum two-core round flame-retardant flexible cable shown in fig. 1, the method for manufacturing the cable comprises the following steps: a step of manufacturing a copper-clad aluminum wire with the copper content of 15-30% into a single conductive wire core 1; an insulation treatment step of performing insulation treatment on the single conductive wire core 1 to form an insulation wire core with an insulation layer 3; cabling two insulated wire cores with the insulating layers 3 to form a cable; and a step of extruding plastic on the cable to form a flame retardant sheath layer 5. Since the cross section of the single conductive wire core 1 is generally circular when the single conductive wire core 1 is manufactured, it is generally not necessary to process the conductive wire core 1 into the conductive wire core 1 having a circular cross section; however, if the cross section of the single conductive wire core 1 is not circular, the conductive wire core 1 needs to be processed into a conductive wire core with a circular cross section.
When manufacturing the single conductive core 1, the cross section of the manufactured single conductive core 1 is generally circular, so that the above-mentioned step of processing the conductive core 1 into the conductive core 1 having a circular cross section can be omitted.
The cabling process comprises the following steps: stranding the two insulated wire cores by using a cabling machine to form a wire harness; a cable insulation 4 is then wrapped around the wire bundle to form a cable.
Since the conductive core 1 shown in fig. 1 is a round core, when two insulated cores are cabled, a considerable space will be present in the cable, which will reduce the strength of the cable. To this end, the cabling process step of the invention further comprises filling a filler 6 between the cable insulation layer 4 and the two insulation layers 3. One specific method of implementing the filling may be, for example: before the wire harness is wrapped around the cable isolation layer 4, the wire harness is wrapped by the filling rope, or the two insulating wire cores and the filling rope are twisted together, and then the cable isolation layer 4 is wrapped. Of course, other filling methods may be used.
For the copper-clad aluminum two-core semicircular flame-retardant flexible cable shown in fig. 2, the method for manufacturing the flexible cable comprises the following steps: a step of manufacturing the copper-clad aluminum wire into a single conductive wire core 1; processing the single conductive wire core into a conductive wire core 1 with a semicircular cross section; an insulation processing step of performing insulation processing on the conductive wire core 1 with a semicircular cross section to form an insulation wire core with an insulation layer 3; cabling two insulated wire cores with the insulating layers 3 to form a cable; and a step of extruding plastic on the cable to form a flame retardant sheath layer 5.
The cabling process comprises the following steps: stranding two insulated wire cores with semicircular cross sections by using a cabling machine to form a wire harness; a cable insulation 4 is then wrapped around the wire bundle to form a cable.
Because the cabled cable comprises two spliced conductive wire cores with semicircular cross sections, the cable is basically filled, namely the cross section of the cable is (solid) circular, so that the compression strength and the bending strength of the cable are increased, the surface area of the conductive wire cores is increased (the transmission loss of communication signals can be reduced), and favorable conditions are created for greatly reducing the outer diameter of the cable. That is, the outer diameter of the cable having the conductive core with the semicircular cross section is greatly reduced as compared with the cable having the conductive core with the circular cross section under the condition that the surface area of the conductive core is not changed.
The insulation treatment steps in the two cable manufacturing methods comprise: firstly, coating a wire core isolation layer 2 on a single conductive wire core 1, and then extruding and coating plastics on the wire core isolation layer 2 to form an insulation layer 3; or directly extruding and wrapping the plastic on the single conductive wire core 1 to form the insulating layer 3.
In addition, in the two manufacturing methods, the wire core isolation layer 2 can be an isolation layer formed by wrapping non-woven fabrics on the conductive wire core; the insulating layer 3 can be formed by extruding flame-retardant polyvinyl chloride or low-smoke halogen-free polyolefin material on the conductive wire core 1; the cable isolation layer 4 can be an isolation layer formed by wrapping non-woven fabrics on the wire harness; the flame-retardant sheath layer 5 can be a sheath layer formed by extruding and wrapping flame-retardant polyvinyl chloride or low-smoke halogen-free polyolefin materials on the cable.
The method for manufacturing the copper-clad aluminum wire into the single conductive wire core 1 comprises the following steps: drawing the copper-clad aluminum wire into a single conductive monofilament 11 by using a drawing machine; annealing the single conductive monofilament 11 by using an annealing machine; using a yarn bundling machine to bundle a plurality of annealed conductive monofilaments into folded yarns; and stranding a plurality of the folded yarns into the conductive wire core 1 by using a stranding machine.
The invention can also omit the step of synthesizing the conductive single filament bundle into the folded yarn, and the step of manufacturing the single conductive wire core 1 is improved as follows: drawing the copper-clad aluminum wire into a single conductive monofilament 11 by using a drawing machine; annealing the single conductive monofilament 11 by using an annealing machine; then, a plurality of annealed conductive monofilaments are stranded into a conductive wire core 1 by a stranding machine.
The twisting together of several conductive monofilaments 11 to form a conductive core 1 is one of the features of the present invention, which makes the cable particularly flexible and flexible.
In the process of drawing the copper-clad aluminum wire into a single conductive monofilament 11, the drawing angle of the copper-clad aluminum wire should be selected to be 12-14 degrees so as to ensure the success of drawing the conductive monofilament.
Since the monofilament is subjected to crystal shift hardening after being drawn, annealing recovery is required, the key of the annealing treatment is the control of annealing temperature, the annealing temperature of pure copper is about 650 ℃, and the annealing temperature of the invention is controlled to be 540 +/-10 ℃.
In the process of bunching and synthesizing the strand, the annealed conductive monofilaments can be bunched according to a certain pitch, wherein the pitch is not more than 14 times of the outer diameter of the strand after bunching; the monofilament can be welded but the strength of the welded part is not less than 85% of the original value.
In the process of twisting a plurality of the strands into the conductive core 1, the plurality of strands may be twisted at a certain pitch.
The conductive wire core is in a structure of twisting a plurality of strands with small diameter, a plurality of strands, so that the conductive wire core is soft, the strength of the copper-clad aluminum wire is not high, and great difficulty is brought to the manufacture of special shapes.
Therefore, the invention adopts the steps of firstly twisting the stranded wires according to the circular arrangement to form the conductive wire core 1 with the circular cross section, and then pressing by using a semicircular forming die. In order to reduce the resistance of the die to the conductor, the invention adopts a 'resistance-free continuous forming' method for pressing, namely, the die is driven to do circular motion by the linear motion of the conductive wire core, the conductive wire core is formed by applying certain pressure, and the surface of the conductive wire core is ensured to be smooth, flat and free of damage.
In addition, when the insulating layer is extruded, in order to ensure the uniformity of the insulating thickness, the invention utilizes a ' mould vacuum method ' (namely, plastic extrusion processing is carried out in a vacuum mould) ' to carry out plastic extrusion processing on the conductive wire core with the semicircular cross section, thereby effectively ensuring the uniformity of the insulating layer.
The copper-clad aluminum two-core flame-retardant flexible cable comprises a copper-clad aluminum two-core round flame-retardant flexible cable shown in figure 1 and a copper-clad aluminum two-core semicircular flame-retardant flexible cable shown in figure 2.
As shown in FIG. 1, the copper-clad aluminum two-core round flame-retardant flexible cable of the invention comprises: a conductive core 1 having an insulating layer 3, the conductive core 1 having a circular cross-section; a cable isolation layer 4 wrapping the two stranded or stranded conductive wire cores 1 with the insulation layers 3; and a flame-retardant sheath layer 5 extruded on the cable isolation layer 4; wherein: the conductive wire core 1 is formed by twisting a plurality of conductive monofilaments 11; each conductive monofilament 11 is composed of an aluminum conductor 111 and a copper cladding 112 covering the aluminum conductor 111.
Wherein each strand of conductive monofilament 11 comprises a plurality of conductive monofilaments 11 bundled together to form a strand.
The copper-clad aluminum two-core round flame-retardant flexible cable also comprises a filling rope 6 filled between the cable isolation layer 4 and the insulation layer 3.
As shown in FIG. 2, the copper-clad aluminum two-core semicircular flame-retardant flexible cable of the invention comprises: a conductive core 1 having an insulating layer 3, the conductive core 1 having a semi-circular cross-section; a cable isolation layer 4 wrapping the two stranded or stranded conductive wire cores 1 with the insulation layers 3; and a flame-retardant sheath layer 5 extruded on the cable isolation layer 4; wherein: the conductive wire core 1 is formed by twisting a plurality of conductive monofilaments 11; each conductive monofilament 11 is composed of an aluminum conductor 111 and a copper cladding 112 covering the aluminum conductor 111.
The two copper-clad aluminum two-core flame-retardant flexible cables can comprise a wire core isolating layer 2 arranged between the conductive wire core 1 and the insulating layer 3.
In addition, the diameter of the conductive monofilament 11 is 0.2-1.2 mm, wherein: the diameter of the aluminum conductor 111 is 0.18439-1.10635 mm, and the thickness of the copper cladding 112 is 0.007805-0.04685 mm, that is, the section of the copper cladding 112 accounts for 15% -30% of the cross section of the whole conductive monofilament 11, and the rest is the section of the aluminum conductor 111.
As described above, in the above two types of cables, the core insulation layer 2 may be a nonwoven fabric insulation layer; the insulating layer 3 can be a flame-retardant polyvinyl chloride or low-smoke halogen-free polyolefin material insulating layer; the cable barrier layer 4 may be a non-woven fabric barrier layer; the sheath layer 5 can be a flame-retardant polyvinyl chloride or low-smoke halogen-free polyolefin material sheath layer.
Preferred but not limiting specifications for the conductive wire core 1 of the present invention are the 18 specifications shown in the following table.
Fig. 4 shows a copper-clad aluminum three-core round flame-retardant flexible cable structure of the invention, and fig. 5 shows a copper-clad aluminum three-core fan-shaped flame-retardant flexible cable structure of the invention. Except for three conductive wire cores, the copper clad aluminum three-core round flame-retardant flexible cable shown in fig. 4 has the same structure as the copper clad aluminum two-core round flame-retardant flexible cable shown in fig. 1. In addition, the cuprum-packing-aluminum three-core round flame-retardant flexible cable shown in fig. 5 has the same structure as the cuprum-packing-aluminum two-core semi-round flame-retardant flexible cable shown in fig. 2 except that the number of the conductive cores is three and the cross section of the conductive core is fan-shaped.
FIG. 6 shows a copper-clad aluminum four-core round flame-retardant flexible cable structure of the invention, and FIG. 7 shows a copper-clad aluminum four-core fan-shaped flame-retardant flexible cable structure of the invention. Except that the number of the conductive wire cores is four, the copper clad aluminum four-core round flame-retardant flexible cable shown in fig. 6 has the same structure as the copper clad aluminum two-core round flame-retardant flexible cable shown in fig. 1. In addition, except that the number of the conductive wire cores is four and the cross section of the conductive wire core is a sector, the copper clad aluminum four-core round flame-retardant flexible cable shown in fig. 7 has the same structure as the copper clad aluminum two-core semi-round flame-retardant flexible cable shown in fig. 2.
Fig. 8 shows a schematic diagram of a copper-clad aluminum five-core round flame-retardant flexible cable structure of the invention, and fig. 9 shows a copper-clad aluminum five-core tile-shaped flame-retardant flexible cable structure of the invention. The copper-clad aluminum five-core round flame-retardant flexible cable shown in fig. 8 is different from the copper-clad aluminum two-core round flame-retardant flexible cable shown in fig. 1 only in that the number of the conductor cores 1 is different. The copper-clad aluminum five-core tile-shaped flame-retardant flexible cable shown in fig. 9 is different from the copper-clad aluminum two-core semicircular flame-retardant flexible cable shown in fig. 2 in that: in the flexible cable shown in fig. 9, the cross section of the conductive core located at the center is circular, and the cross sections of the remaining four conductive cores surrounding the central conductive core are in a tile shape, thereby combining into one wire harness having a circular cross section; in the flexible cable shown in fig. 2, two wire cores with semicircular cross sections are spliced to form a wire harness with a circular cross section.
The principle of the flame-retardant cable is as follows: the adopted insulating and sheathing materials are provided with a flame retardant, and the flame retardant has the functions of isolating the cable from the outside air, prolonging the burning time of the cable and effectively preventing the extension of flame when a fire disaster happens, and the flame of the cable is self-extinguished within 5 seconds when the cable leaves an open fire.
In addition to the flame retardant flexible cable described above, the present invention also provides a flame retardant, fire resistant flexible cable. The flame-retardant and fire-resistant flexible cable is realized by arranging the flame-retardant layer in the cable. The material of the fire-resistant layer mainly comprises a mica layer and a glass fiber layer, and the material has the characteristics of excellent insulating property, fire resistance and heat resistance, and can keep 90-minute electrified operation in flame.
The specific implementation mode for realizing flame retardance and fire resistance is that the wire core isolating layer 2 is made into a wire core fire-resistant layer, the wire core fire-resistant layer comprises a mica layer wrapped on the outer surface of the single conductive wire core 1 and a glass fiber layer wrapped on the outer surface of the mica layer, and the cable isolating layer 4 is made into a cable fire-resistant layer.
For example, in the copper clad aluminum two-core round flame retardant flexible cable structure of the invention shown in fig. 10 and the copper clad aluminum two-core round flame retardant flexible cable structure of the invention shown in fig. 11, the core isolation layer 2 is made into a core flame retardant coating, which comprises a mica layer 21 wrapped on the outer surface of the single conductive core 1 and a glass fiber layer 22 wrapped on the outer surface of the mica layer 21; furthermore, the cable insulation layer 4 is also made as a cable fire-resistant layer. The other construction of the flexible cable shown in fig. 10 and 11 is the same as that of the flame-retardant flexible cable shown in fig. 1 and 2, and thus is a flame-retardant and fire-resistant flexible cable. By analogy, the copper-clad aluminum three-core, four-core and five-core flexible cables shown in fig. 4 to 9 can also be formed into flame-retardant fire-resistant flexible cables in a similar way.
It should be noted that, in addition to the flexible cable with multiple conductive cores, the flexible cable of the present invention may also be a flexible cable with a single conductive core. The invention can therefore be summarized as:
the invention discloses a method for manufacturing a copper-clad aluminum flexible cable, which comprises the following steps:
a step of manufacturing a copper-clad aluminum wire with the copper content of 15-30% into a single conductive wire core 1;
an insulation treatment step of performing insulation treatment on the single conductive wire core 1 to form an insulation wire core with an insulation layer 3;
cabling treatment is carried out on one or more insulation wire cores with the insulation layers 3 to form a cable; and
extruding plastic on the cable to form a flame-retardant sheath layer 5.
Wherein the cabling process comprises:
stranding the plurality of insulation wire cores by using a cabling machine to form a wire harness;
a cable insulation 4 is then wrapped around the wire bundle to form a cable.
Or,
stranding the plurality of insulation wire cores and the filling rope 6 by using a cabling machine to form a round wire harness;
and then, winding a cable isolation layer 4 on the round wire harness to form a cable.
The invention discloses a method for manufacturing a copper-clad aluminum flexible cable, which comprises the following steps:
a step of manufacturing a copper-clad aluminum wire with the copper content of 15-30% into a single conductive wire core 1;
processing a single conductive wire core into a conductive wire core 1 with a semicircular or fan-shaped or tile-shaped cross section;
an insulation processing step of performing insulation processing on the conductive wire core 1 with a semicircular or fan-shaped or tile-shaped cross section to form an insulation wire core with an insulation layer 3;
cabling treatment is carried out on one or more insulation wire cores with the insulation layers 3 to form a cable; and
extruding plastic on the cable to form a flame-retardant sheath layer 5.
Wherein the cabling process comprises the steps of:
stranding a plurality of insulated wire cores with semicircular or fan-shaped or tile-shaped cross sections by using a cabling machine to form a wire harness;
a cable insulation 4 is then wrapped around the wire bundle to form a cable.
The method for manufacturing the copper-clad aluminum wire into the single conductive wire core 1 comprises the following steps:
drawing the copper-clad aluminum wire into a single conductive monofilament 11 by using a drawing machine;
annealing the single conductive monofilament 11 by using an annealing machine;
using a yarn bundling machine to bundle a plurality of annealed conductive monofilaments into folded yarns;
and stranding a plurality of the folded yarns into the conductive wire core 1 by using a stranding machine.
The wire core isolation layer 2 can be made into a wire core fire-resistant layer, and the wire core fire-resistant layer comprises a mica layer 21 wrapped on the outer surface of the single conductive wire core 1 and a glass fiber layer 22 wrapped on the outer surface of the mica layer 21; and making the cable insulation layer 4 into a cable fire-resistant layer. By this treatment, the flexible cable of the present invention has a function of fire resistance.
Wherein the drawing angle of the single conductive monofilament 11 drawn by the copper-clad aluminum wire is 12-14 degrees. (ii) a The annealing temperature in the annealing treatment is controlled to be 540 +/-10 ℃.
In addition, the copper-clad aluminum flexible cable of the invention comprises:
a conductive core 1 having an insulating layer 3, the conductive core 1 having a circular cross-section;
the cable isolation layer 4 wraps one or more conductive wire cores 1 with the insulation layers 3; and
the flame-retardant sheath layer 5 is extruded on the cable isolation layer 4; wherein:
the conductive wire core 1 is formed by twisting a plurality of conductive monofilaments 11;
the conductive monofilament 11 is composed of an aluminum conductor 111 and a copper cladding 112 covering the aluminum conductor 111, wherein the copper cladding 112 accounts for 15% -30% of the volume of the conductive monofilament, and the aluminum conductor 111 accounts for 85% -70% of the volume of the conductive monofilament.
The other copper-clad aluminum flexible cable comprises:
a conductive core 1 with an insulating layer 3, the cross section of the conductive core 1 is semicircular or fan-shaped or tile-shaped;
the cable isolation layer 4 wraps one or more conductive wire cores 1 with the insulation layers 3; and
the flame-retardant sheath layer 5 is extruded on the cable isolation layer 4; wherein:
the conductive wire core 1 is formed by twisting a plurality of conductive monofilaments 11;
the conductive monofilament 11 is composed of an aluminum conductor 111 and a copper cladding 112 covering the aluminum conductor 111, wherein the copper cladding 112 accounts for 15% -30% of the volume of the conductive monofilament, and the aluminum conductor 111 accounts for 85% -70% of the volume of the conductive monofilament.
The diameter of the conductive monofilament 11 is 0.2-1.2 mm, the diameter of the aluminum conductor 111 is 0.18439-1.10635 mm, and the thickness of the copper clad layer 112 is 0.007805-0.04685 mm.
The cable of the invention has the advantages that: less copper, light weight and low cost. Because of the adoption of a monofilament structure with a plurality of small diameters and a multi-strand stranding process, the cable is particularly flexible and can be bent randomly.
Although the present invention has been described in detail hereinabove, the present invention is not limited thereto, and various modifications can be made by those skilled in the art in light of the principle of the present invention. Thus, modifications made in accordance with the principles of the present invention should be understood to fall within the scope of the present invention.
Claims (10)
1. A copper-clad aluminum flexible cable manufacturing method comprises the following steps:
the method for manufacturing the single conductive wire core (1) by the copper-clad aluminum wire with copper occupying 15% -30% of the volume of the copper-clad aluminum wire comprises the following steps:
drawing the copper-clad aluminum wire into a single conductive monofilament (11) by using a drawing machine;
annealing the single conductive monofilament (11) by using an annealing machine;
using a yarn bundling machine to bundle a plurality of annealed conductive monofilaments into folded yarns;
stranding a plurality of the strands into a conductive wire core (1) by using a stranding machine;
an insulation processing step of performing insulation processing on the single conductive wire core (1) to form an insulation wire core with an insulation layer (3);
cabling treatment is carried out on one or more insulation wire cores with the insulation layers (3) to form a cable; and
extruding plastic on the cable to form a flame-retardant sheath layer (5).
2. The method of claim 1, wherein the cabling process comprises:
stranding the plurality of insulation wire cores and the filling rope (6) by using a cabling machine to form a round wire harness;
and then, winding a cable isolation layer (4) on the round wire harness to form the cable.
3. The method according to claim 2, wherein the cable insulation layer (4) is a cable fire-resistant layer.
4. A method according to claim 3, wherein the drawing angle for drawing the copper-clad aluminum wire into a single conductive monofilament (11) is 12-14 °; the annealing temperature in the annealing treatment is controlled to be 540 +/-10 ℃.
5. The method according to claim 1, wherein the conductive monofilament (11) has a diameter of 0.2 to 1.2mm, the aluminum conductor (111) has a diameter of 0.18439 to 1.10635mm, and the copper cladding (112) has a thickness of 0.007805 to 0.04685 mm.
6. A copper-clad aluminum flexible cable manufacturing method comprises the following steps:
the method for manufacturing the single conductive wire core (1) by the copper-clad aluminum wire with copper occupying 15% -30% of the volume of the copper-clad aluminum wire comprises the following steps:
drawing the copper-clad aluminum wire into a single conductive monofilament (11) by using a drawing machine;
annealing the single conductive monofilament (11) by using an annealing machine;
using a yarn bundling machine to bundle a plurality of annealed conductive monofilaments into folded yarns;
stranding a plurality of the strands into a conductive wire core (1) by using a stranding machine;
the diameter of the conductive monofilament is 0.2-1.2 mm, the diameter of the aluminum conductor is 0.18439-1.10635 mm, and the thickness of the copper cladding is 0.007805-0.04685 mm;
processing a single conductive wire core into a conductive wire core (1) with a semicircular or fan-shaped or tile-shaped cross section;
an insulation processing step of performing insulation processing on the conductive wire core (1) with the cross section of a semicircle or a fan shape or a tile shape to form an insulation wire core with an insulation layer (3);
cabling a plurality of insulated wire cores with the insulating layers (3) to form a cable; and
extruding plastic on the cable to form a flame-retardant sheath layer (5).
7. The method of claim 6, wherein the step of cabling comprises:
stranding a plurality of insulated wire cores with semicircular or fan-shaped or tile-shaped cross sections by using a cabling machine to form a wire harness;
and then, winding a cable isolation layer (4) on the wire harness to form the cable.
8. The method according to claim 7, wherein the cable insulation layer (4) is a cable fire-resistant layer.
9. The method according to claim 8, wherein the drawing angle for drawing the copper-clad aluminum wire into a single conductive monofilament (11) is 12-14 °; the annealing temperature in the annealing treatment is controlled at 540+10 ℃.
10. The method according to claim 6 or 7, wherein the conductive monofilament (11) has a diameter of 0.2 to 1.2mm, the aluminum conductor (111) has a diameter of 0.18439 to 1.10635mm, and the copper cladding (112) has a thickness of 0.007805 to 0.04685 mm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN2008101668698A CN101685684B (en) | 2008-09-27 | 2008-09-27 | Copper-clad aluminum flexible cable and manufacturing method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN2008101668698A CN101685684B (en) | 2008-09-27 | 2008-09-27 | Copper-clad aluminum flexible cable and manufacturing method thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN101685684A CN101685684A (en) | 2010-03-31 |
| CN101685684B true CN101685684B (en) | 2012-05-23 |
Family
ID=42048784
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2008101668698A Active CN101685684B (en) | 2008-09-27 | 2008-09-27 | Copper-clad aluminum flexible cable and manufacturing method thereof |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN101685684B (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102208372B (en) * | 2011-05-19 | 2015-12-02 | 华进半导体封装先导技术研发中心有限公司 | A kind of high-density conducting channel base plate and manufacture method thereof |
| CN105070407A (en) * | 2013-04-19 | 2015-11-18 | 江苏亨通线缆科技有限公司 | Processing mechanism of power supply flexible cable for power supply of telecommunication equipment |
| CN107993736A (en) * | 2017-11-29 | 2018-05-04 | 铜陵市东方矿冶机械有限责任公司 | Copper alloy wire |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1034701C (en) * | 1993-05-13 | 1997-04-23 | 张明阳 | High flame resistant cable |
| CN1230754A (en) * | 1998-03-26 | 1999-10-06 | 彭星魁 | Compound copper-aluminium wire and its production process |
| CN2423639Y (en) * | 2000-06-06 | 2001-03-14 | 朱克超 | Overloading fire-resistant electric wire |
| CN1828783A (en) * | 2005-03-04 | 2006-09-06 | 日立电线株式会社 | Non-halogen flame resistant wire and cable |
| CN2836181Y (en) * | 2005-10-11 | 2006-11-08 | 天津金山电线电缆股份有限公司 | Low-smoke nontoxic flame-retardant power cable |
| CN2919466Y (en) * | 2006-06-23 | 2007-07-04 | 宝胜科技创新股份有限公司 | Communication calbe with copper-clad aluminum core |
-
2008
- 2008-09-27 CN CN2008101668698A patent/CN101685684B/en active Active
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1034701C (en) * | 1993-05-13 | 1997-04-23 | 张明阳 | High flame resistant cable |
| CN1230754A (en) * | 1998-03-26 | 1999-10-06 | 彭星魁 | Compound copper-aluminium wire and its production process |
| CN2423639Y (en) * | 2000-06-06 | 2001-03-14 | 朱克超 | Overloading fire-resistant electric wire |
| CN1828783A (en) * | 2005-03-04 | 2006-09-06 | 日立电线株式会社 | Non-halogen flame resistant wire and cable |
| CN2836181Y (en) * | 2005-10-11 | 2006-11-08 | 天津金山电线电缆股份有限公司 | Low-smoke nontoxic flame-retardant power cable |
| CN2919466Y (en) * | 2006-06-23 | 2007-07-04 | 宝胜科技创新股份有限公司 | Communication calbe with copper-clad aluminum core |
Also Published As
| Publication number | Publication date |
|---|---|
| CN101685684A (en) | 2010-03-31 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN101335114B (en) | Method for manufacturing copper coated aluminum dual-core flame-retardant refractory flexible electric cable | |
| CN101335110B (en) | Copper coated aluminum three-core flame-retardant flexible electric cable and manufacturing method thereof | |
| CN101685684B (en) | Copper-clad aluminum flexible cable and manufacturing method thereof | |
| CN104835576A (en) | Combined control cable and preparation method therefor | |
| CN101335118B (en) | manufacturing method for copper coated aluminum uni-core flame-retardant flexible electric cable with double sheathf | |
| CN101335115B (en) | Method for manufacturing copper coated aluminum dual-core flame-retardant flexible electric cable | |
| CN201233750Y (en) | Copper coated aluminum three-core flame-retardant flexible electric cable | |
| CN201191520Y (en) | Copper coated aluminum dual-core flame-retardant refractory flexible electric cable | |
| CN101335119B (en) | Copper coated aluminum uni-core flame-retardant flexible electric cable manufacturing method | |
| CN101335113B (en) | Copper coated aluminum four-core flame-retardant refractory flexible electric cable and manufacturing method thereof | |
| CN201233752Y (en) | Copper coated aluminum dual-core flame-retardant flexible electric cable | |
| CN101335111B (en) | Method for manufacturing copper coated aluminum three-core flame-retardant refractory flexible electric cable | |
| CN101335112B (en) | Copper coated aluminum four-core flame-retardant flexible electric cable manufacturing method | |
| CN101335109B (en) | Method for manufacturing copper coated aluminum five-core flame-retardant flexible electric cable | |
| CN201233749Y (en) | Copper coated aluminum five-core flame-retardant refractory flexible electric cable | |
| CN201233746Y (en) | Copper coated aluminum four-core flame-retardant flexible electric cable | |
| CN101335116B (en) | Copper-clad aluminum single-core flame-retardant fire-resistant double-sheath flexible cable manufacturing method | |
| CN201233748Y (en) | Copper coated aluminum five-core flame-retardant refractory flexible electric cable | |
| CN201233745Y (en) | Copper coated aluminum three-core flame-retardant refractory flexible electric cable | |
| CN101335117B (en) | Copper coated aluminum uni-core flame-retardant refractory flexible electric cable manufacturing method | |
| CN101335108B (en) | Copper-clad aluminum five-core flame-retardant fire-resistant flexible cable manufacturing method | |
| CN222394590U (en) | Multifunctional spring wire for mobile central control display screen of automobile | |
| CN201233747Y (en) | Copper coated aluminum four-core flame-retardant refractory flexible electric cable | |
| CN214624489U (en) | Cable structure and home decoration wiring cable | |
| CN201247637Y (en) | Copper coated aluminum uni-core flame-retardant flexible cable |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| PB01 | Publication | ||
| C10 | Entry into substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant | ||
| CP01 | Change in the name or title of a patent holder |
Address after: 215542 Changshou City Southeast Economic Development Zone, Jiangsu Patentee after: JIANGSU ZHONGLI GROUP Co.,Ltd. Address before: 215542 Changshou City Southeast Economic Development Zone, Jiangsu Patentee before: ZHONGLI SCI-TECH GROUP Co.,Ltd. |
|
| CP01 | Change in the name or title of a patent holder | ||
| TR01 | Transfer of patent right | ||
| TR01 | Transfer of patent right |
Effective date of registration: 20180213 Address after: 215542 Southeast Economic Development Zone, Changshu, Suzhou, Jiangsu Co-patentee after: JIANGSU FAVOUR AUTOMOTIVE NEW STUFF SCI-TECH Co.,Ltd. Patentee after: JIANGSU ZHONGLI GROUP Co.,Ltd. Co-patentee after: CHANGZHOU MARINE CABLE Co.,Ltd. Co-patentee after: CHANGSHU ZHONGLIAN PHOTOELECTRICITY NEW STUFF Co.,Ltd. Co-patentee after: GUANGDONG ZHONGDE CABLE Co.,Ltd. Address before: 215542 Changshou City Southeast Economic Development Zone, Jiangsu Patentee before: JIANGSU ZHONGLI GROUP Co.,Ltd. |
|
| TR01 | Transfer of patent right | ||
| TR01 | Transfer of patent right |
Effective date of registration: 20220207 Address after: 215500 Changshu Southeast Economic Development Zone, Suzhou City, Jiangsu Province Patentee after: JIANGSU ZHONGLI GROUP Co.,Ltd. Patentee after: CHANGZHOU MARINE CABLE Co.,Ltd. Patentee after: CHANGSHU ZHONGLIAN PHOTOELECTRICITY NEW STUFF Co.,Ltd. Patentee after: GUANGDONG ZHONGDE CABLE Co.,Ltd. Address before: 215542 Changshu Southeast Economic Development Zone, Suzhou City, Jiangsu Province Patentee before: JIANGSU ZHONGLI GROUP Co.,Ltd. Patentee before: JIANGSU FAVOUR AUTOMOTIVE NEW STUFF SCI-TECH Co.,Ltd. Patentee before: CHANGZHOU MARINE CABLE Co.,Ltd. Patentee before: CHANGSHU ZHONGLIAN PHOTOELECTRICITY NEW STUFF Co.,Ltd. Patentee before: GUANGDONG ZHONGDE CABLE Co.,Ltd. |
|
| TR01 | Transfer of patent right | ||
| TR01 | Transfer of patent right |
Effective date of registration: 20221117 Address after: 215500 Changshu Southeast Economic Development Zone, Suzhou City, Jiangsu Province Patentee after: JIANGSU ZHONGLI GROUP Co.,Ltd. Patentee after: CHANGZHOU MARINE CABLE Co.,Ltd. Patentee after: CHANGSHU ZHONGLIAN PHOTOELECTRICITY NEW STUFF Co.,Ltd. Address before: 215500 Changshu Southeast Economic Development Zone, Suzhou City, Jiangsu Province Patentee before: JIANGSU ZHONGLI GROUP Co.,Ltd. Patentee before: CHANGZHOU MARINE CABLE Co.,Ltd. Patentee before: CHANGSHU ZHONGLIAN PHOTOELECTRICITY NEW STUFF Co.,Ltd. Patentee before: GUANGDONG ZHONGDE CABLE Co.,Ltd. |