The wire and cable manufacturing industry is an industry of material finishing and assembly. The amount of cable materials is huge, and the material costs in cable products account for 80-90% of the total manufacturing cost. There are many types and varieties of materials, and the performance requirements are particularly high. For example, copper is required to have a purity of 99.95% or more. Some products must use oxygen-free high-purity copper; the selection of cable materials will have a decisive impact on the manufacturing process, product performance and service life.
The materials used in 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 the materials are common to several structural parts. Especially thermoplastic materials, such as polyvinyl chloride, polyethylene, etc., can be used on insulation or sheaths as long as part of the composition is changed.
Name and material of product structure
(1) Wire: The most basic and essential component for the product to carry out electric current or electromagnetic wave information transmission function.
Main material: Conductor is the abbreviation of conductive core, made of copper, aluminum, copper-clad steel, copper-clad aluminum and other non-ferrous metals with excellent conductivity, and optical fiber is used as the conductor.
There are bare copper wire, tinned wire; single branch wire, stranded wire; tinned wire after twisting.
(2) Insulation layer: It is a component that is wrapped around the periphery of the wire and plays an electrical insulation role. That is, it can ensure that the transmitted current, electromagnetic waves, and light waves only travel along the wire and do not flow to the outside, and the potential on the conductor (that is, the potential difference formed to the surrounding objects, that is, the voltage) can be isolated, that is, it is necessary to ensure the normal transmission of the wire Function, but also to ensure the safety of external objects and people. Wire and insulation are the two basic components that must be equipped to form cable products (except bare wires).
Main materials: PVC, PE, XLPE, polypropylene PP, fluorine plastic F, rubber, paper, mica tape
(3) Filling structure: Many wire and cable products are multi-core. After these insulated cores or pairs are cabled (or grouped into multiple cables), one is that the shape is not round, and the other is that there is a gap between the insulated cores. There is a large gap, so a filling structure must be added when the cable is formed. The filling structure is to make the outer diameter of the cable relatively round in order to facilitate the wrapping and squeezing of the sheath.
Main material: PP rope
(4) Shield: It is a component that isolates the electromagnetic field in the cable product from the external electromagnetic field; some cable products also need to be isolated between different wire pairs (or wire groups) inside. It can be said that the shielding layer is a kind of “electromagnetic isolation screen”. The conductor shielding and insulation shielding of high-voltage cables is to homogenize the electric field distribution.
Main materials: bare copper wire, copper clad steel wire, tinned copper wire
(5) Protective layer: When wire and cable products are installed and operated in various environments, they must have a component that protects the entire product, especially the insulating layer, which is the protective layer.
Because insulating materials are required to have excellent various electrical insulating properties, they must require extremely high purity of the material and minimal impurity content; it is often unable to take into account its ability to protect the outside world, so for the outside world (ie installation, use occasions and ) The endurance or resistance of various mechanical forces, resistance to atmospheric environment, resistance to chemicals or oils, prevention of biological damage, and reduction of fire hazards must be borne by various protective layer structures.
Main materials: PVC, PE, rubber, aluminum, steel belt
(6) Tensile components: The typical structure is steel core aluminum stranded wire, fiber optic cable, etc. In short, in the developed special small, flexible products that require multiple bends and twists at the same time, the tensile elements play a major role.
Main material: steel wire
