Method of electric conductor manufacturing

FIELD: electricity.

SUBSTANCE: method of electric conductor manufacturing includes introduction of an additive consisting of a mix of heat-resistant organosilicone fluid (OSF) and heat-resistant fluororganic compound (FOC) in the amount of 0.3-1.5% by weight into granulate of radiation-synthesized compound based on copolymer of tetrafluoroethylene and ethylene. Proportion of OSF and FOC varies within limits of 1:3 up to 3:1. The obtained mixture of granulate and additive is delivered to a loading hopper of the extrusion machine, thereafter at least one coating of this mixture is applied as insulation to electric conductor and irradiated. Electric strength of conductor is more than 70 kV/mm.

EFFECT: improving manufacturability and productivity of the suggested method due to exclusion of destruction of radiation-synthesized compound at growth rate of its application to conductor, high physical and mechanical and electrical properties of insulation.

3 tbl, 1 ex

 

The invention relates to a method of manufacturing electric wires and can be used in aviation, aerospace, shipbuilding and other industries.

A known method of manufacturing electric wires, including extrusion and drawing fluoropolymer composition based on a copolymer of tetrafluoroethylene and hexaferrite on a conductive core (US patent # 7723615, H01B 7/00, 2010).

The disadvantage of this method is the low adaptability and efficiency of the process due to high temperature processing, low-speed process that leads to the release of volatile gaseous products during extrusion

The closest in technical essence of the present invention is a method for manufacturing an electric wire including supply of radiation-stitched composition based on a copolymer of tetrafluoroethylene and ethylene, which is used as insulation in an extruder and applying at least one insulation layer on a conductive core with subsequent irradiation (RU, patent No. 63110, H01B 11/00, 2007).

The disadvantage of this method is low efficiency and productivity of the manufacturing process of the electric wire and its quality due to degradation and partial crosslinking of the radiation-stitched composition due to the high temperature and n is scoi speed of the extrusion process.

The invention solves the problem of manufacturing electric wires with high technical characteristics. The technical result is to increase the manufacturability and performance of the manufacturing process of the electric wire and its quality by eliminating degradation of the radiation-stitched composition by lowering the temperature in the extruder and the speed of deposition of the radiation-stitched composition on the conductive core.

The technical result is achieved in the method of manufacturing an electric wire including an introduction to radiation-stitched composition based on a copolymer of tetrafluoroethylene and ethylene, which is used as insulation, the additive consisting of a mixture of heat-resistant silicone fluid and heat resistant organofluorine compounds in the amount of 0.3 to 1.5 wt. -%, the feed radiation-stitched composition in the extruder, causing at least one insulation layer on a conductive core with further irradiation, the ratio of heat-resistant silicone fluid and heat resistant organofluorine compounds is from 1:3 to 3:1.

Distinctive features of the proposed method of manufacturing electric wires are introduction prior to feeding into the extruder in radiation-stitched composition on the basis of which Polimer tetrafluoroethylene and ethylene additive, consisting of a mixture of heat-resistant silicone fluid and heat resistant organofluorine compounds in the amount of 0.3 to 1.5 wt. -%, the ratio of heat-resistant silicone fluid and heat resistant organofluorine compounds is from 1:3 to 3:1. Introduction to radiation-stitched composition of the additive consisting of heat-resistant silicone fluids and heat-resistant organofluorine compounds, allows you to increase the speed of extrusion and to reduce the temperature of the extrusion process due to the use of compounds with higher melt flow index. Heat-resistant silicone fluid is a low molecular weight silicone rubber, having the consistency of butter and high chemical resistance. These quality silicone fluids help to increase the wettability of the granules radiation-stitched composition, to improve the chemical resistance of the composition when the heating mode and get grease the inner walls of the extruder. Heat-resistant organofluorine compound is a fluoroelastomer (copolymer of tetrafluoroethylene with a diene and/or olefin)having a similar nature to the polymer substrate (a copolymer of tetrafluoroethylene and ethylene) radiation-stitched composition, which leads to greater compatibility of organofluorine compounds and polimernoi fundamentals of composition and eliminates the interface between these components and to improve the homogeneity of the mixture. The amount of additive, 0.3 to 1.5% mass is optimal for the extrusion process. The selection of the ratio of heat-resistant silicone fluid and heat resistant organofluorine compounds is from 1:3 to 3:1, which is optimal for producing electric wires with high physico-mechanical, thermal and electrical properties, in particular, high abrasion resistance, high tensile strength after crosslinking 45 MPa, high thermal stability (absence of delamination and shrinkage isolation after aging at 200°C for 500 hours), no insulation breakdown at a voltage of 1500 V AC frequency 50 Hz, high dielectric strength more than 70 kV/mm

A method of manufacturing electric wires as follows.

In the granulate radiation-stitched composition based on a copolymer of tetrafluoroethylene and ethylene, which is used as insulation, injected additive consisting of a mixture of heat-resistant silicone fluid (KO) and heat-resistant organofluorine compounds (FD), in the amount of 0.3-1.5% of masstone heat-resistant silicone fluids and heat-resistant organofluorine compounds is from 1:3 to 3:1. The mixture of granulate and supplements served in the hopper of the extruder. Then hold the drawing at the ore of one layer of the mixture (isolation) on a conductive core followed by radiation.

Example

1 kg of granulate radiation-stitched composition based on a copolymer of tetrafluoroethylene and ethylene was injected additive in quantities of 10, the Radiation-stitched composition is a pellet containing a polymer base is a copolymer of tetrafluoroethylene and ethylene, a crosslinking agent, triallylisocyanurate and inorganic filler is titanium dioxide. The additive consists of a mixture of 5 g of heat-resistant silicone fluid, Dow Corning 550 and 5 g of heat-resistant organofluorine compounds Dynamar FX 5922. The amount of additive is 1% of the mass, and the ratio of heat-resistant silicone fluid and heat resistant organofluorine compounds is from 1:1. The mixture was mixed in the mixer with a speed of no more than 50 rpm and served in the hopper of the extruder, which is the main node extrusion line Kuhne, which is a direct application of insulation. The main part of the extruder is working cylinder with 7 heating zones, within which is placed a sleeve, made of special wear-resistant alloy steel, which is tightly pressed into the cylinder and is heated by electric heaters or induction type. The main working tool of the extruder is a screw, which is located inside the cylinder liners, Zack is aplan console, having support in bearings designed for high axial loads. The auger is driven by motor through reducer. It has a spiral threaded, which is located on the working side, a substantial length. Depending on the type of extruder and the type of material being processed in the working length of the screw in the 20-35 times greater than its diameter.

The resulting mixture was periodically applied to the hopper of the extruder. Rotating the worm captures the feed material, which is heated, compacted, melted, homogeneities and moving through the screw thread of the screw enters the cylinder of the extruder, where is the forming tool (Dorn and matrix), which provides for the imposition of a given layer coating on a conductive core

As the conductors used tinned stranded copper tin wire nominal cross-section of 0.35 mm2. On a conductive core inflicted two insulation layer with a total thickness of 0.2 mm with the thickness of the first and second layers, respectively, 0,098 mm and is 0.102 mm Deviation from the nominal thickness +10%.

Table 1 shows the temperature of the heating zones for each insulation layer.

Table 1
No. The amount of additive and the ratio of CO and FOZone heating, °CThe process speed, m/minNote
p/p1234567
10,2250260270280280290300201 layer
0,5:3250250270280280290290202 layer
20,3250250260270270 270260351 layer
1:1250250260270270260260352 layer
31,0250250260260260260260351 layer
1:3250250260260260260250352 layer
41,5250250260260260260 250351 layer
3:1250250260260260260250352 layer
51,7250260260280280290290231 layer
a 3.5:1250260260280280290290232 layer

From table 1 it is seen that when the optimal values of the number of additives and the ratio of heat-resistant silicone fluid and heat resistant organofluorine compounds, respectively, 0.3 to 1.5 wt%. and 1:3 to 3:1 (examples 2-4) the extrusion process takes place p and lower temperatures and higher speeds in comparison with examples 1 and 5, where the amount of additive and the ratio of CO and FO are outside the upper and lower limits.

The received electrical wire insulation was subjected to irradiation for crosslinking insulation on the production line, which includes the accelerator ILU-8 1 MeV. The dose is 8-12 Mrad, mainly 9-10 Mrad.

Table 2 shows the results of testing the electrical wires after stitching, justifying the choice of additive amount.

Table 2
№p/pQuantity of the additive, wt.%The ratio of CO and FOTPP stapled g/10 min 300°C/5 kgAppearance isolationElectr. strength, kV/mmAbrasion resistance (needle diameter of 0.6 mm at prijemnom effort 5,9 N)The resistance to bending, the number of cyclesThe process speed, m/min
10,21:10color isolation white, smooth surface of the insulation, there are some thickening in the form of cones68 75090020
20,31:10color isolation white, smooth surface of the insulation without flaws and inclusions72950110035
31,01:10color isolation white, smooth surface of the insulation without flaws and inclusions731000110035
41,51:10color isolation white, smooth surface of the insulation without flaws and inclusions731000110035
51,71:10color isolation white, smooth surface of the insulation, there are small nodules90090023

Table 2 shows that with the introduction of additives in the amount of 0.3 to 1.5 wt%. the process speed is increased by 40%-50%, improved mechanical and electrical properties of the wire, the surface of the insulation smooth without defects and inclusions. With the introduction of the additive amount is less than 0.3 and greater than 1.5% of the mass. the rate of the process decreases, physical-mechanical and electrical properties of the wire is significantly lower, and the surface of the insulation is defective.

Table 3 shows the results of testing the electrical wires after stitching, justifying the selection of the ratio of silicone fluid and organofluorine compounds.

Table 3
№p/pThe ratio
the decision TO and FO
Quantity of the additive, wt.%TPP stapled g/10 min 300°C/5 kgAppearance isolationElectr, strength, kV/mmAbrasion resistance (needle diameter of 0.6 mm at prijemnom effort 5,9 NThe resistance to bending, the number of cyclesSoon the efficiency of the process, m/min
11:31,00color isolation
white, smooth surface of the insulation without flaws and inclusions
71820102035
21:11,00color isolation
white, smooth surface of the insulation without flaws and inclusions
74950110035
33:11,00color isolation
white, smooth surface of the insulation without flaws and inclusions
73980110035
40,5:31,00color isolation
white, smooth surface of the insulation, there are some uelsen the cones
6978094019
5a 3.5:11,00color isolation white, smooth surface of the insulation, there are small nodules7079098022

From table 3 it can be seen that when the ratio of heat-resistant silicone fluid and heat resistant organofluorine compounds from 1:3 to 3:1, the process speed is increased by 35%-45%, improved mechanical and electrical properties of the wire, the surface of the insulation smooth without defects and inclusions. When the ratio of heat-resistant silicone fluid and heat resistant organofluorine compounds is less than 1:3 and above 3:1, the rate of the process decreases, physical-mechanical and electrical properties of the wire is significantly lower, and the surface of the insulation is defective.

The proposed method of manufacturing electric wires allows to obtain a wire with high technical characteristics, to improve manufacturability and performance of the manufacturing process of the electric wire and its quality. In the electric wire with crosslinked insulation has a high chemical and radiation resistance and can be used in temperatures ranging from minus 65 to 200°C.

A method of manufacturing an electric wire including supply of radiation-stitched composition based on a copolymer of tetrafluoroethylene and ethylene, which is used as insulation in an extruder and applying at least one insulation layer on a conductive core with subsequent irradiation, characterized in that before applying the radiation-stitched composition in the extruder it is additionally injected additive consisting of a mixture of heat-resistant silicone fluid and heat resistant organofluorine compounds in the amount of 0.3-1.5 wt.%, the ratio of heat-resistant silicone fluid and heat resistant organofluorine compounds is from 1:3 to 3:1.



 

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