Wire And Cable Structural Materials

The vast majority of wire and cable products are the section (cross section) shape is exactly the same (ignore the error caused by manufacturing), long strip products, which is due to the system or equipment is used as a line or coil of the characteristics determined. Therefore, study and analyze the structure of cable products, only observe and analyze from its section.

The structural components of wire and cable products can be divided into four main structural components: wire, insulation layer, shielding and shield layer, as well as filling elements and bearing components. According to the product use requirements and application occasions, some product structure is extremely simple.

2. Cable materials

In a sense, the wire and cable manufacturing industry is a material fine processing and assembly industry. First, the material consumption is huge, the material cost of cable products should account for 80-90% of the total manufacturing cost; second, the types of materials and varieties, the performance requirements are particularly high, such as the conductor copper purity should be above 99.95%, some products should use oxygen free high purity copper; third, the selection of materials will have a decisive impact on the manufacturing process, product performance and service life.

At the same time, the benefit of wire and cable manufacturing enterprises is also closely related to the scientific saving of materials in material selection, processing and production management.

Therefore, in the design of wire and cable products must be carried out at the same time with the selection of materials, generally take the selection of several materials, through the process and performance screening test is determined.

The materials used for cable products can be divided into conductive materials, insulating materials, filling materials, shielding materials and protective layer materials according to their use parts and functions. But some of these materials are common for several structural parts. In particular, thermoplastic materials, such as PVC, polyethylene, can be used as long as part of the formula is changed in insulation or sheath.

The materials used in the manufacturing of cable products involve a very wide range of categories, and the varieties and specifications (grades) are particularly many.

3. Name and material of the product structure

(1) wire: the product for current or electromagnetic wave information transmission function of the most basic essential main components.

Main material: the wire is short for the conductive wire core, made of copper, aluminum, copper clad steel, copper clad aluminum and other non-ferrous metals with excellent conductive performance, with optical fiber as a wire.

There are bare copper wire and tin line; single branch line and stranded line and stranded tin line.

(2) Insulation layer: is wrapped in the conductor around the periphery of the role of electrical insulation components. That is to ensure that the transmission of current or electromagnetic waves, light waves only along the wire and do not flow to the outside, the conductor has the potential (that is, the potential difference formed by the surrounding objects, that is, the voltage) can be isolated, that is, not only to ensure the normal transmission function of the wire, but also to ensure the safety of external objects and people. Lead and insulation layer are two basic components that must constitute cable products (except bare wire class).

Main materials: PVC, PE, XLPE, polypropylene PP, fluorinated plastic F, rubber, paper, mica belt

(3) filling structure: many wire and cable products are core, the insulation core or line into cable (or grouped into cable), one is the shape is not round, the second is a large gap between the insulation core, so must be added into the cable fill structure, filling structure is to make the cable outer diameter relatively round to facilitate belt, crowded sheath.

Main material: PP rope

(4) Shield: it is a component that separates the electromagnetic field of cable products from the external electromagnetic field; some cable products have different line pairs (or line groups) inside them. It can be said that the shielding layer is a kind of "electromagnetic isolation screen". The conductor shielding and insulation shielding of the high voltage cables are designed to balance the distribution of the electric field.

Main materials: bare copper wire, copper clad steel wire, tinned copper wire

(5) Cover: when the wire and cable products are installed and run in a variety of different environments, it must have the protective role of the whole product, especially the insulation layer, which is the cover.

Since the insulation material has excellent electrical insulation properties, it requires high purity and minimal impurity content; and often fails to protect the outside world, so the mechanical resistance, atmospheric environment, chemicals or oils, and reduce the hazards of fire must be borne by various protective layer structures.

Main materials: PVC, PE, rubber, aluminum, steel strip

(6) tensile element: the typical structure is steel core aluminum stranded, optical fiber and cable, etc. In short, the development of special small, soft, and requires the use of the product, the tensile element plays a major role.

Main material: steel wire