PVC wire extruder

In today's era of rapid development of power transmission and electronic equipment, PVC insulated wire is a key carrier for energy transmission and information transmission, and the performance of its production equipment is crucial. PVC wire extruders, as the core equipment of the cable manufacturing industry, shoulder the important task of accurately transforming PVC materials into wire insulation, which directly determines the quality and performance of wires.

How it works:

PVC wire extruders use a series of precise processes to transform PVC particles into a continuous, uniform layer of insulation that is wrapped around the surface of the conductor. Its work process mainly includes the following key steps:

Raw material pretreatment: PVC resin is thoroughly mixed with various additives such as plasticizers, stabilizers, colorants, etc., in precise proportions. This aspect is crucial and directly impacts the thermal stability, flexibility, and appearance and performance of the final product. For example, in the production of weather-resistant wires, specific anti-UV additives are added to ensure that the wires are used in outdoor environments for a long time without aging.

Melt plasticization: The mixed raw material enters the screw extrusion system, where the temperature rises rapidly to 200 - 220°C in the heating cylinder. The high-speed rotation of the screw pushes the raw material forward, while it is strongly sheared and stirred, so that the PVC particles gradually melt and form a gel with high fluidity. In this process, the design parameters of the screw, such as the length-to-diameter ratio and the depth of the screw groove, play a decisive role in the plasticization effect. Taking a screw with a larger diameter as an example, it can provide a longer plasticization path, allowing the raw material to fully melt and mix at higher temperatures and pressures, thereby improving the plasticization quality.

Precision Extrusion: The molten PVC is evenly encased on the conductor surface through a carefully designed mold (machine head). The structure and dimensional accuracy of the mold directly determine the thickness uniformity of the insulation layer and the dimensional accuracy of the outer diameter. For some wires that require extremely high insulation performance, such as high-voltage cables, the mold is manufactured with an accuracy of up to the micron level to ensure that the deviation of the insulation layer thickness is controlled within a very small range.

Cooling shaping: The extruded wire immediately enters the cooling system, which can be water-cooled or air-cooled. In the fast cooling setting: the extruded wire immediately enters the cooling system, which can be water-cooled or air-cooled. During rapid cooling, the PVC insulation cures rapidly, creating a stable structure that maintains its shape and dimensional accuracy. Water cooling systems usually have the advantages of fast cooling speed and high efficiency, and are suitable for large-scale production; The air-cooled system is more environmentally friendly and has a better cooling effect on some thin-walled wires, which can avoid problems such as cracking of the insulation layer caused by too fast cooling.

Technical advantages

High efficiency and high precision: Real-time monitoring and adjustment of various parameters during the extrusion process can accurately control the eccentricity of the insulation layer within 5%, ensuring uniform insulation thickness, greatly improving the electrical performance and safety of the wire. For example, in the production of communication cables, high-precision insulation layers can effectively reduce attenuation and interference during signal transmission, ensuring stable and reliable communication quality.

Superior material adaptability: In addition to being able to perfectly process standard PVC formulations, this equipment also offers excellent material compatibility and can easily handle the extrusion needs of a wide range of modified materials such as LSZH, flame retardant (FR - PVC), etc. By optimizing key components such as screw length-to-diameter ratio and thread edged structure, the screw's ability to convey and mix materials can be significantly enhanced, and the dispersion uniformity of additives such as flame retardants in the PVC matrix can be increased by more than 40%, thereby ensuring the stable performance of the modified material during the extrusion process and producing high-quality wires that meet different industry standards. Whether it is the wiring of public buildings with extremely high environmental requirements or the manufacture of automotive wiring harnesses with strict regulations on fire resistance, this equipment can handle it with ease.

Outstanding energy-saving and environmental protection characteristics: In terms of energy consumption, the traditional resistance heating method is abandoned and advanced electromagnetic induction heating technology is adopted. This heating method acts directly on the screw and barrel, and the heat transfer efficiency is higher.

Precise temperature control system: Equipped with a digital temperature control system, independent and precise temperature control of different areas of the extruder. The zonal temperature control accuracy can reach ±1°C, which can adjust the temperature in real time according to the characteristics of the material and process requirements, avoid problems such as thermal degradation and poor plasticization of materials due to too high or too low temperature, and ensure the stability and consistency of product quality. For example, in the production of special high-temperature resistant wires, precise temperature control can ensure that the PVC material has stable performance during high-temperature extrusion without decomposition or deterioration.

Applications:

Building wiring: It is the basic material for building electrical installation, and the BV wire (single-core hard conductor unsheathed cable) and BVR wire (multi-core soft conductor unsheathed cable) are widely used in the power wiring system of various buildings such as homes, office buildings, and shopping malls. Its good insulation properties and mechanical strength can ensure the safe and reliable transmission of power during long-term use, ensuring the normal operation of various electrical equipment in the building.

Automotive industry: The electrical system inside the car is complex, and the performance requirements of the wires are extremely demanding. The temperature-resistant 105°C thin-walled low-voltage conductor produced by this equipment has excellent high temperature resistance, oil resistance, wear resistance, can work stably in harsh environments such as automobile engine compartment and chassis, and provide stable power and signal transmission for automobile lighting, ignition, sensors and other systems, and is an indispensable key component of modern automobile manufacturing.

New energy field: With the vigorous development of new energy industries such as solar and wind energy, the demand for supporting cables is also growing. As an important part of the solar power generation system, photovoltaic cables need to have good UV resistance, weather resistance, and electrical properties. The UV-resistant PVC sheathed photovoltaic cable produced by this equipment can effectively resist the erosion of the outdoor environment, ensure that the cable can still maintain stable performance under long-term sun exposure, wind and rain erosion, and provide a reliable guarantee for the efficient use of new energy.

Communication cables: In the 5G era, communication networks place higher requirements for the speed and stability of data transmission. The PVC insulated communication cables produced by this equipment can meet the needs of high-speed data transmission with their high-precision insulation layer and low signal attenuation characteristics, and are widely used in infrastructure construction such as communication base stations and data centers, building a solid bridge for the rapid transmission of information.

With its advanced technology, excellent performance, and wide applicability, PVC wire extruders are ideal for cable manufacturing companies to enhance their competitiveness and achieve efficient production.