JPH0340884A - Making of corrosion resistant cable - Google Patents

Abstract

PURPOSE: To obtain an anticorrosion cable suitable for a brake cable, etc., for an automotive by coating a wire with an anticorrosion coating solution and stranding the coated wire. CONSTITUTION: This anticorrosion cable is preferably obtained by coating a wire obtained by plating with zinc and washing to remove contaminants such as oil or grease with an aticorrosion solution obtained by mixing an alkyl silicate such as tetraethyl orthosilicate and zinc such as zinc dust into an organic solvent such as isopropanol, binding and stranding, then evaporating an organic solvent by drying, hydrolyzing the alkyl silicate, polymerizing and forming a coating film of an inorganic silicate and zinc and preferably covering with a plastic.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention The present invention relates to a method for manufacturing a cable comprising multiple strands of metal wire. In particular, the present invention relates to a method of manufacturing a corrosion-resistant wire cable. The invention is particularly suitable for manufacturing brake cables and the like.

BACKGROUND OF THE INVENTION Metal wire cables quickly begin to corrode in outdoor environments without protection. Although galvanizing provides some protection, additional protection is required, especially in corrosive outdoor environments where there is frequent exposure to water and salt. For this reason, automotive brake cables are usually coated or coated with plastic. Plastics may provide effective protection for a time, but eventually stress corrosion cracking occurs due to the combined effect of tensile stress and the corrosive environment. Typically, such stress corrosion cracking occurs within a vehicle's approximately 50,000 miles of driving time. Cracking can cause sudden and unexpected breakage of the brake cable. There is a need for better ways to protect such cables.

[Problems to be Solved by the Invention] The present invention seeks to provide a method for manufacturing a corrosion-resistant cable.

[Means for Solving the Problem] The problem can be solved by applying a corrosion-resistant coating solution to the wires when manufacturing the cable of stranded (preferably pre-galvanized) wires. The solution can be any organic based alkyl silicate-zinc mixture. The organic solvent evaporates and the alkyl silicate ester is hydrolyzed and upon exposure to air polymerizes to form an inorganic silicate film on the wire. The membrane contains approximately 80-90% zinc. After the coating has dried (i.e. after the film has formed)
, the cable is coated with (thermoplastic) plastic.

The invention makes it possible to significantly increase the life expectancy of cables, especially when the method of the invention is used to manufacture cables such as brake cables used in corrosive environments, such as water and salt, as well as environments subject to tensile stresses. can.

Automotive brake cables made by the method of the present invention have been found to resist cracking and breakage after the vehicle has been driven for over toooo miles.

The method of the invention is suitable for cables of any type comprising steel, iron, iron alloys or other metals, or metal alloy wires that tend to corrode in the presence of water or salt or in normal outdoor environmental conditions. Also suitable for manufacturing. As used herein, "cable" or "wire cable"
is understood to include cables as well as wire ropes, multistrand or filamentary wires and similar twisted wire products. The metal wire selected for manufacturing the cable according to the method of the invention may be untreated wire, but is preferably a galvanized metal wire.

The wire is also preferably shiny (ie, clean) or cleaned or cleaned of oil, grease, and other contaminants for use in cable manufacturing. In the cable manufacturing method of the present invention, the corrosion-resistant coating solution applied to the wire adheres most smoothly and evenly when the wire is free of oil and other contaminants.

In the practice of the invention, the apparatus and method for bundling and twisting wire into cables may be those commonly used in the adaptations of the invention described below. An applicator for applying the anti-corrosion solution, preferably the applicator shown in FIG. 1, is placed at the point where the strands of wire constituting the cable are to be twisted together into a cable.

The applicator die 11 is arranged adjacent to the strand closing die 12, and the wires 13 constituting the cable are bundled together in the applicator die 11, passed through the reservoir of the corrosion-resistant solution 14 in the die, and then Send it to 12. Either a pressure pump (not shown) with a meter to control the flow rate or a conduit from a supply tank (not shown) at a controlled rate! 5 to feed the anti-corrosion solution into the reservoir. The feed tank is airtight and preferably equipped with a stirrer to maintain the integrity and homogeneity of the corrosion-resistant coating solution M14. Another type of applicator used in the present invention may be an extruder that extrudes the corrosion resistant coating solution onto the wire instead of having a reservoir of solution through which the wire passes.

It may also be any other mechanical means suitable for applying a controlled amount of solution to the wire.

The amount of corrosion-resistant coating solution applied to the wire is
It may vary depending on the use of the wire, the viscosity of the solution, and the rate of application of the solution. The most effective amount of solution in this invention is the amount that will completely coat the wire, leave no streaks of uncoated wire, and provide a cable that meets the desired level of corrosion resistance for the cable's application. It is. For example, approximately 400 to 600
Time (measured according to salt spray test method, ASTM B-17)
A level of corrosion protection of is preferred and can be achieved by the method of the invention. This increase in the level of corrosion protection is due to
This is particularly important in the automobile industry. Prior to implementing the method of the present invention, the typical best corrosion protection level achieved in practice for brake cables was approximately 96 hours (as measured by the Salt Spray Test Method, ASTM B-17). When applying a corrosion resistant coating solution having a viscosity of approximately 200 to 300 cps, an "effective" amount of such solution is typically 1
The amount is deposited on the wire at a flow rate of about 500-850 x Q per 1000 feet of 78 inch wire strand. For brake cables made with e.g. 7 wires in the core and e.g. 12 wires in the outer layer, the following amounts of corrosion-resistant coating solution are effective: The amount is approximately 100-200* per 1,000 feet of wire strand
The amount of solution for the outer layer of 12 wires is the amount that will be deposited on the wire at a flow rate of Q: The amount of solution for the outer layer of 12 wires is the amount that will be deposited on the wire at a flow rate of about 400 to 650 villages per 1000 feet of wire strand.

In any case, the rate of application of the corrosion-resistant coating solution in the method of the invention should not exceed the rate at which the wire can be completely coated with the solution.

Fluorescent dyes may be added to the corrosion-resistant coating solution to easily detect (under UV light) wires that are not completely coated. The preferred amount of dye is 0.05 to 0.17 in alcohol, preferably isopropyl alcohol.
% dissolved amount. Preferably, each wire making up the cable is completely coated with a corrosion-resistant solution.

Corrosion-resistant coating solutions suitable for the method of the invention are organic-based zinc alkyl silicate mixtures. Any alkyl silicate ester that is hydrolyzed and then polymerized in the presence of air to form a film of inorganic silicate may be used. Any organic material that evaporates into air at room temperature and does not react with the alkyl silicate or zinc may be used as a base. Preferred organic-based alkyl silicate solutions suitable for the practice of this invention are available from Orscheln Co.
[Moberly, Missouri
ORS, which is commercially available from
IL: Trademark). Orsil is an organic solvent base,
Preferably monohydroxy alcohols, such as isopropanol, ethanol and/or methanol,
Tetraethylorthosilicate (or tetramethylsilicate; tetraethylorthosilicate is preferred)
and mica (approximately 3-9% by weight) and small amounts (approximately 0.03-9% by weight)
2.5%) of moisture scavengers and anti-settling agents. Thickener may be added to increase the desired viscosity. Based on these, the required amount of zinc dust or fine powder is applied to the wire and when dried in air (i.e., evaporates the organic solvent and hydrolyzes the alkyl silicate ester, inorganic silicate or when polymerizing an inorganic matrix of inorganic silicates),
The amount is such that the resulting dry film on the wire contains about 80-90% zinc.

Corrosion-resistant coating solutions used in the present invention may be coated by methods known to those skilled in the art.

The method described below using Orsil is a typical example. Homogenize the orsil in a sealed stainless steel or plastic mixing tank. Slowly add fine zinc powder to approximately 50-75% by weight of Osil (100-150 bonds/
time) and mix in an explosion-proof mixer equipped with a stainless steel stirrer.

Mixing is done at a minimum of about 2
Preferably, it is carried out at a moderate speed of 0 Orpm. Only a slight vortex is created on the surface of the mixture to prevent air from being entrained in the solution. ignition,
Take normal explosion precautions. Mixing time varies depending on the amount of osyl and zinc used. Mix until the solution is homogeneous with no lumps and no zinc separation or surface streaks. 10% fluorescent dye solution and alcohol, usually 2 lbs.
Add ~8 pairs. After mixing, the coating solution is filtered using a 30 mesh or less filter and stored in a sealed, airtight stainless steel or plastic container until use. Alternatively, the solution may be filtered immediately before use, or in addition to being filtered after mixing, it may also be filtered immediately before use. The shelf life of this coating solution is
Approximately 48 hours. Viscosity is generally 200-300cp
s [70°F (21'C), Brookfield Viscometer, 20 rpm, Spindle No. 2], but the mixture may be further diluted by diluting with alcohol. The flash point of the solution is about 50-65°F (10-18°C) (ASTM D93).

Furthermore, when carrying out the invention, i.e. manufacturing the cable following the application of the wire as described above, the coating is allowed to fully cure. Approximately 12-7 in normal atmospheric conditions
Within 2 hours, the coating is completely dry. If the humidity is high, drying will be slow. The coating may be quickly dried in a vented gas or electric oven. In this case, the temperature is about 250-450°F (121-232°C) and the time is about 3-10 hours.

After drying the coating, the cable is preferably coated with thermoplastic. Typical thermoplastics suitable for use in brake cables produced by the method of the invention are copolyester type plastics.

[Example] The present invention will be explained in more detail with reference to the following example.

The example illustrates the application of the method of the invention to the production of a cable comprising an outer layer of 12 wires twisted around a core of 7 stranded wires. In both examples below, each wire making up the cable is completely coated with a corrosion-resistant coating solution according to the method of the invention. In each example, completeness of the application was confirmed by monitoring the fluorescence of the strands under UV light during cable processing.

Example 1 Orsil 100 bond with a viscosity of 300 cps was introduced into an explosion-proof mixer equipped with a stainless steel stirrer. 60 bonds of fine zinc powder with a particle size of 6 microns per hour
20 Bond was slowly added to the Orsil, preferably using a screw feeder and mixed at 200 rpm. After the zinc powder was added to the Orsil, approximately 500 x ff of a 10% alcoholic solution of fluorescent dye was added. Total mixing time was approximately 45 minutes. The mixed coating solution was then filtered through a 20 mesh filter.

The viscosity of the resulting solution was approximately 250 cps.

After mixing, the solution was applied to the wires (galvanized and oil-free) within 24 hours by the following two steps: First, the seven wires that were bundled and twisted to form the core of the cable were The solution was applied at a flow rate of 200xe per 1000 feet of strand; the 12 wires were then bundled and twisted into 7 core wires to obtain a corrosion-resistant cable with 7 core wires and 12 outer layer wires. The solution was applied at a flow rate of 650 H per 1000 feet of wire strand.

The coated wire strand cable was spooled onto a reel (45,000 feet of cable in a straight line) and kept at room temperature [
80″F (27°C)] and 55% humidity for 24 hours.
Dry in the air. After drying, the cable was coated with plastic using an extruder. Salt spray test (ASTM B
-117), the cable showed corrosion protection performance for an average of 550 hours.

Example 2 Fine zinc powder 25 bond with a particle size of 6 microns was added to Orsil 50 bond with a viscosity of 200 cp using a screw feeder at a rate of 120 bonds per hour.
Mixed on Orpm. After mixing Osil with zinc, a 10% isopropyl alcohol solution of fluorescent dye
0 villages were added. Total mixing time was 30 minutes. The zinc was well dispersed and the mixture was filtered using a 30 mesh filter. The resulting solution was diluted with isopropyl alcohol 1000a+j until the viscosity was 200 cps. This diluted solution was then applied to the galvanized wire at a rate of 100i per 10OO feet for a 7 wire process (core) and 400xQ per 1000 feet for a 12 wire process (outer layer).
It was applied at a speed of Cable of coated strands (4
5000 feet) was wound onto a reel and dried in a vented gas oven for 8 hours at 350" P (177° C.) before extrusion coating the outside of the cable with plastic.

As a result of the salt spray test (ASTM B 117), the cable exhibited corrosion protection performance for an average of 600 hours.

The idea of the present invention and the best mode to which this idea is applied have been described. The foregoing is by way of example only, and other means and techniques may be used without departing from the scope of the invention as claimed.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view of an applicator for applying an anti-corrosion solution to a wire during the manufacture of a cable according to the method of the invention. DESCRIPTION OF SYMBOLS 11... Applicator die, 2... Cruising die, +3 Wire 14... Corrosion-resistant coating solution, 15... Conduit.

Claims (1)

[Claims] 1. A method for manufacturing a corrosion-resistant wire cable, which comprises applying a corrosion-resistant coating solution to the cable wire when manufacturing the cable by twisting the wires. 2. When manufacturing a cable by twisting wires, apply a corrosion-resistant coating solution to the wires that make up the cable, dry the coating on the wires that make up the cable, and cover the cable with plastic. A method of manufacturing a corrosion-resistant wire cable comprising: 3. The method of claim 2, wherein the wire is galvanized prior to applying the corrosion resistant coating solution. 4. The method of claim 2, wherein the wire is cleaned to remove oil, grease, and other contaminants before applying the corrosion resistant coating solution. 5. The method of claim 2, wherein all wires making up the cable are completely coated with the corrosion-resistant coating solution. 6. The corrosion-resistant coating solution is an organic-based alkyl silicate-zinc mixture, and the base evaporates and the alkyl silicate hydrolyzes and polymerizes in the presence of air to form an inorganic silicate and a zinc mixture on the wire. 3. The method of claim 2, further comprising forming a zinc film. 7. The method of claim 2, wherein the coating on the wire when dry consists essentially of about 80-90% inorganic silicates and zinc. 8. The method of claim 2, wherein said drying is carried out in air. 9. Claim 8, wherein the drying time is about 12 to 72 hours.
Method described. 10, the drying in a ventilated oven, about 250-45
3. The method of claim 2, wherein the method is carried out at 0<0>F. 11. Claim 1, wherein the drying time is about 3 to 10 hours.
The method described in 0. 12. The coating solution is about 200-300 cps
3. The method of claim 2, wherein the wire has a viscosity of 100 ml and is applied to the wire at a rate that allows the wire to be completely coated. 13. The method of claim 2, wherein the coating solution comprises an alcoholic solution of a fluorescent dye. 14. Strands of galvanized metal wire are used in the manufacture of cables, and the strands are cleaned to remove contaminants such as oil and grease, and when the wires begin to be twisted to form cables, an organic base material is used. applying an alkylsilicate-zinc solution to the cable, fully twisting the strands into a cable, drying the coating on the strands forming the cable, and coating the cable with plastic. A method of manufacturing an automobile brake cable consisting of: