Fluoro热塑料导线挤压涂层(1)

A3MCompanyFluoro-thermo-plasticWireExtrusioncoatingPerNelsonErikPetersDyneonLLCA3MCompanyTopics•Polymers•ConductorPayoff•Sizing/cleaning•Preheating•Extruder•Crosshead•Tooling•Cooling•Gauges•TroubleshootingA3MCompanyDyneonFEP,PFA,ETFE,THVPolymerGradeDensityMFIBurnResist.DielectricconstantDielectricloss,tandASTMD2863DIN/VDE0303/Teil4ASTMD150ASTMD150g/cm³g/10minLOI@50Hzto106Hz@1kHz,RT@1MHz,RTET6210J1.7311-14297/530-3562358.5-11.56235J6-82.6=0.0007=0.0066240J9-11FEPX63032.12-2.173372/595X630772.050.0002=0.0007632222=0.0009PFA6510N2.1510372/595=2.050.000010.00016515N15X6525N25THV2201.9520265/5617-0.145001.9810755.6-0.1A3MCompanyPolymerusesPolymerGradeMainEndapplicationAdvantageET6210Jthinwallinsulation6235Jautomotive(motorcompartment)verygoodstress-crackresistanceatelevatedtemperature6240Jmedicalequipmentallowshigherprocessing-speedFEPX6303jacketingthickwallinsulation,betterstresscrackresistanceX6307appliances,illumination,datacables,heattracecablesmoderatetype,goodheatresistance6322plenum,datacables,telecomhighprocessing-speed,verythinwallthicknessPFA6510Nheattracecablesthickwallinsulation,excellentheatresistance6515Nheattracecables,automotive(lambazone)moderatetype,excellentheatresistanceX6525NdatacableshigherprocessingspeedTHV220jacketing(robotics)veryhighflexibility500jacketing(robotics)highflexibilityA3MCompanyPolymerlinespeedsLinespeedDimensions(diameter)FEP6322550m/min0.5mmcore0.9mmtotalFEPX630760m/min0.5mmcore1.0mmtotalPFA651554m/min0.5mmcore1.0mmtotalETFE6235J30m/min0.5mmcore1.0mmtotalA3MCompanyPayoff•Options–Flier–Roll-off–Inlinedraw•Flowstabilityiscrucial–backtensionafterflier–tensionbrakeA3MCompanySizing/cleaning(solidconductors)•Introducestensiontoline•Cleanscoppersurface•Improvedcoppersurface;improvedelectricaltransmissionA3MCompanyCopperPreheating•Indicators–Highpreheat•Voidedinnersurface•Smoothoutersurface•Betteradhesionstrip–Lowpreheat•Roughoutersurface•Pooreradhesion•Recommendations–Temperatureguidelines•FEP/PFA100-180C•ETFE/THV50C•Dependsonlinespeed–Measurement•Paper–goodcomparativetest–universalA3MCompanyExtruder•Extruderspec’s–L/D24-34:1–Saxtonmixing2-4xdiameter–Closeheatcontrolnecessaryforastableprocess–corrosionprotectedmaterialnickelalloy–Extruderneedstohaveatleast400CmaximumtemperatureA3MCompanyCrosshead•Specs–Fixedoradjustablecenter–Corrosionprotectedmaterialconstruction–Coex/singleextrusionpossibleA3MCompanyTubing•Whytubeextrusion?A3MCompanyMeltfractureSmoothsurface‚Sharkskin‘ExtrudedfilmTubingA3MCompanyToolingDDRBalanceLandFEP100-1201.01-2cmPFA701.01-2cmETFE20-401.01-2cmTHV20-401.01-2cmA3MCompanyToolingcalculationsDDR=(DD²-DT²)/(dCC²-dW²)DRB=(DD/dCC)/(DT/dW)dCCDDDTdWA3MCompanyCone•Indicators–Toolong•Diametervariation•Unstable–Tooshort•surfaceroughness•sparks/pinholes•conebreaks–Unstable•Tipanddienotconcentric•Corenotcentered•Melttoohotorcold•Linespeedtoohigh•Recommendations–30-40mmA3MCompanyCoolingTroughAirGapWatertempTotallengthFEPhighspeed7m75C20mFEP2m50C10mPFA2m50C10mETFE2m50C10mA3MCompanyCapstan•Coldwaterspraytypical•GroovedsheavespreferableoverstationaryguidesA3MCompanyGauges/Indications•Linetension–gaugeofinstability–Identifyconductordamage•Inner(copper)diameter–coppersizeandquality•Capacitance–crucialforfoam–adhesionproblems–eccentricityproblems–diameterproblemsA3MCompanyGauges/Indications•Outerdiameter–Productsize–Long-termvariation–ovality•Eccentricity–Coppercenter•Lump/neckdown–Shorttermvariation•Sparktester–holes,thinspotsA3MCompanyTroubleshootingPrimarysymptomSecondarysymptomTertiarysymptomTroubleshootingstepsOutersurfaceroughOneside/asymmetricalNobubblesCenterthecrosshead/copperDecreaseconelengthRaisepreheatLowermelttemperatureEqualizemelttempsbetweenco-extrudersBubblesininsulation(co-extrusion)IncreaseextruderspeedonextruderwithbubblingDecreasetemperaturesinextruderwithbubblingDryFEPpriortoextrusionSymmetricalNobubblesIncreaseconelengthIncreasecopperpreheatDecreasemelttemperatureBubblesininsulationDecreasemelttemperatureDryFEPpriortoextrusionA3MCompanyTroubleshootingPrimarysymptomSecondarysymptomTertiarysymptomTroubleshootingstepsInnersurfaceofinsulationroughCopperqualityDirtyoroilycopperUsewipes,finishingdiePre-heaterVoids,blistersLowerpreheattemperatureShrink-backand/orlowstripforceTensionLowerlinetensionDancertensionEliminatelongfreesuspendedwireonlineCoolingIncreasewatertemperatureonupstreamendofthelineDecreasewatertemperatureincapstan/downstreamend(relativetoupstream)ReplacelongerfloodedtroughsectionswithsprayorspotfeedA3MCompanyTroubleshootingPrimarysymptomSecondarysymptomTertiarysymptomTroubleshootingstepsBubblesininsulation/moltenFEPExtrusionDiscolorationDecreaseextrudertemperaturesIncreasethetemperaturerangeintheextruderandcrossheadbydecreasingatthefeedendIncreasescrewspeedContaminationTryuncontaminatedFEPPre-extrusionNodiscolorationinFEPDryorpreheatFEPA3MCompanyTroubleshootingPrimarysymptomSecondarysymptomTertiarysymptomTroubleshootingstepsDiameterVariation(seealso“roughwire”)LinestabilityPossiblevibrationCheckfor:wornsheaves,wireoutofintendedpath,al