In the manufacturing process of silicone rubber cables, ensuring a strong and unbreakable bond between the conductor and insulation layer is crucial for guaranteeing stable cable performance and lifespan. Achieving this goal relies on comprehensive control over material selection, process management, equipment optimization, and quality inspection.
Material selection is fundamental. Silicone rubber, as the insulation material, must possess excellent high-temperature resistance and aging resistance, while also exhibiting good compatibility with the conductor material. The conductor typically uses tin-plated copper wire; its tin plating not only improves conductivity but also enhances adhesion to the silicone rubber. During material procurement, strict quality control is essential to ensure the purity and performance indicators of the silicone rubber meet standard requirements, preventing poor adhesion due to material defects.
Process control is critical. During conductor stranding, the stranding pitch and tension must be carefully controlled to ensure a tight and uniform conductor structure, preventing poor contact between the conductor and insulation layer due to loose conductors. The silicone rubber mixing process is also vital. During mixing, pure silicone rubber or reinforcing compound must be thoroughly mixed with compounding agents to ensure uniform filler dispersion and prevent the formation of hard filler lumps. Simultaneously, strict control of mixing temperature and time is necessary to prevent overheating of the rubber compound, which could lead to premature vulcanization or performance degradation. During insulation extrusion, extrusion temperature and speed parameters must be optimized to ensure the silicone rubber uniformly coats the conductor, forming a good bonding interface.
Equipment optimization is crucial. Manufacturing silicone rubber cables requires specialized extrusion equipment, such as steam continuous vulcanizing extruders or salt bath continuous vulcanizing extruders. These devices must possess precise temperature control capabilities and stable extrusion pressure to ensure the silicone rubber maintains suitable flowability and vulcanization during extrusion. Furthermore, the cleanliness of the equipment must be strictly controlled to avoid contamination that could lead to performance degradation or poor bonding. During extrusion, the equipment's operating status must be checked regularly, and parameters adjusted promptly to ensure the continuity and stability of the production process.
Quality inspection is critical. After cable manufacturing, rigorous quality inspection is required, including visual inspection, dimensional measurement, and electrical performance testing. Among these, bond strength testing is a vital indicator for evaluating the adhesion between the conductor and insulation layer. Tensile tests or peel tests can be used to verify whether the bond strength between the conductor and insulation layer meets standard requirements. For substandard products, the causes must be analyzed promptly and corrective measures implemented to prevent problematic products from entering the market.
Environmental control is also crucial. The manufacturing environment for silicone rubber cables must be kept clean and dry to prevent dust, moisture, and other impurities from contaminating the rubber compound and the product. Simultaneously, the ambient temperature must be controlled within a suitable range to avoid changes in rubber compound properties or incomplete vulcanization due to excessively high or low temperatures.
Furthermore, continuous improvement and innovation are essential for enhancing the bonding quality of silicone rubber cables. By developing new silicone rubber materials, optimizing production processes, and introducing advanced production equipment, the performance and quality of cables can be continuously improved to meet market demands for high-quality cables.
