美规线材制造讲义

FLEXIBLE CORD & FIXTURE WIRE講義一.名詞解釋XTW : parallel Integral, Decorative-Lighting Cords, 300V 105℃CXTW : Twisted Pair & Single Conductor, Decorative-Lighting Cords, 300V 105℃S(Service) : Heavy duty, rubber-insulated and rubber jacketed overall, 600VSE : Same as S, using thermoplastic Elastomer in place of rubberSEO : Same as SE, but with Oil resistance out jacketSJ : Junior hard service, same as S but300V, thickness differentSJO : Same as SJ, but with Oil resistance out jacketSJE : Same as SJ, using thermoplastic Elastomer in place of rubberSJEO : Same as SJE, but with Oil resistance out jacketSJEOO : Same as SJE, but with Oil resistance out jacket and insulationSJEOW : Same as SJE, Sunlight and Oil resistance out jacket, wet locationSV : Vacuum cleaner cord, rubber insulated and jacketed, light duty in damp locationsSVO : Same as SV, but with Neoprene Oil resistance out jacketSVE : Same as SV, using thermoplastic Elastomer in place of rubberSVEO : Same as SVE, but with Oil resistance out jacketSJT : Same as SJ, using Thermoplastic in place of rubberSJTO : Same as SJT, but with Oil resistance out jacketSJTOO : Same as SJT, but with Oil resistance out jacket and insulationSJTOOW : Same as SJTOO, Sunlight resistance out jacket, wet locationSVT : Same as SV, using Thermoplastic in place of rubberSVTO : Same as SVT, but with Oil resistance out jacketST : Hard service cord, Same as S, using Thermoplastic in place of rubberSTW : Same as ST, Sunlight resistance out jacket, wet locationSRD : Portable range or dryer cable, rubber insulated and jacketed, flat or round construction SRDE : Same as SRD, using thermoplastic Elastomer in place of rubberSRDT : Same as SRD, using Thermoplastic in place of rubber, 90℃SP-1 : all rubber, parallel-jacketed, light duty cord use in damp locations, 300VSP-2 : Same as SP-1, but heavier construction, 300VSP-3 : Same as SP-2, but heavier construction, 300VSPE-1,2,3 : Same as SP-1,2,3, using thermoplastic Elastomer in place of rubberSPT-1,2,3 : Same as SP-1,2,3, using Thermoplastic in place of rubberNISPT-1,2 : Nonintegral SPT-1,2 insulation and jacket all ThermoplasticHPN : Heater Parallel Neoprene cord, use in damp locationsCL2 : Class 2 General Purpose remote control, power-limited cable, meets Vertical Tray flame CL3 : Class 3 General Purpose remote control, power-limited cable, meets Vertical Tray flame CM : Communication cable, meets Vertical Tray flame testCMX : Outdoor Communication cable, meets VW-1 flame testCMG : Communication cable General PurposeCMR : Communication cable Riser, meets Riser flame testCMP : Communication cable Plenum, meets Steiner tunnel flame test二.導体截面積算法截面積: 1. mm2=(單根導体外徑(mm))2 x 0.7854 x導体條數(N)2. cmil or CM(圓密爾) : (密爾(mil))2 x 導体條數(N)1mil=(1/1000)英吋=0.0254mm 所以1”=39.37mil , 則CM=(39.37 x單根導体外徑(mm))2 x N各AWG導体的使用,其最小截面積必須符合UL1581的規定,例如:18AWG截面積需大於等於0.823 mm2 or 1620CM. UL1581規定如下: (表1)三.線材說明及安規要求1.生產流程:2.測試項目(UL62 & 1581) :a.芯線顏色: (表2)b.芯線絞距: (表3)c.各材料物性:絕緣材料: (表4)外被材料: (表5)(a.)一般線材: 室溫中放於水中6小時,其最小值為Class43 &12B之PVC : 2.5 megohm*kftClass12A &12C之PTFE, FEP : 1000 megohm*kft(b.)W線材: 分”常溫短期”,”高溫短期”&”長期放於水中的IR變化率”三項(1.) 常溫短期之絕緣電阻值(6hr): (表6)(2.) 高溫絕緣電阻值(6hr): (表7)(3.) 長期放於水中的IR變化率:浸泡於50.0 0C水中6星期後,IR若大於3 megohms*km,且續測的每週之衰減值不小於4%,則測12個星期即可.若大於表7.的值但小於3 megohms*km,則需測24~36個星期,且續測的每週之衰減值不得小於2%,否則試驗即告失敗.e.機械強度(Mechanical Strength): (表8)f. 耐電壓&火花試驗(RMSTest Potentials) : (表9)耐電壓&火花試驗(RMSTest Potentials) : (續表9)g.加熱變形(Deformation) : 1-T2 /T1( T1 : 老化前厚度; T2 : 老化後厚度)加熱變形荷重: (表10)3.UL印字規定: 字距在610mm以內,且需包含以下內容:(UL) Mark; 公司名稱or 商標; E number; Cord type(ex.SVT); Conductors(ex.18/3);溫度等級(大於最小溫度60 0C才需印); 電壓等級.4.PVC材料特性:a.軟硬度(Hardness):線材以SHORE A表示,插頭以P數(可塑劑對100單位PVC的含量)表示.由於各製造商配方不同,同樣P數的材料其SHORE A可能不同,兩者對照參考如下: (表11)為參考值.b.非移行性(Non-migration):一般試驗條件以60 0C(or 70 0C x 24hrs x 500g(or 1kg)為主,試驗板為ABS or PS.所謂移行,乃指可塑劑析出侵蝕ABS or PS板稱之.所以此類PVC之可塑劑需使用高分子聚酯型(ex. PN-1030),且搭配非鉛系安定劑使用.HIPS板較PS板更較ABS板易受侵蝕,所以要通過HIPS板試驗時,其配方成本最高,且較不易生產,有時得再回押一至二次,以改善麻點問題.c.低鉛鎘(Lead free)PVC :PVC中,鉛鎘主要來自安定劑,其次為色料及Sb2O3(耐燃劑),所以要達到低鉛要求除了需改用非鉛鎘系安定劑外,色料及Sb2O3也需慎用.目前檢測重金屬之設備可分為原子吸收光譜儀(Atomic Absorption,AA)與等離子體發散光譜儀(Induce Coupled Plasma / Atomic Emission Spsctrometer orOptical Emission Spsctrometer, ICP/AES or ICP/OES).兩者差異如下: (表12)測試方法及規範如下:EN71 (歐洲) EPA3050B (USEPA 美國環保局) ST-96 (日本) ASTM963-96 (美國) 91/338/EEC (歐洲) AS1647 (澳洲) 94/62/EC (歐洲) Philips 001 (飛利浦內規) EN1122 (歐洲)各標準最大檢出量要求如下: 單位: ppm(mg/kg) (表13)飛利浦內規(PHS001) (表14)PBBE : P oly b rominated B iphenyl E thers ; PBB : P oly b rominated B iphenylsPCB : P oly c hlorinated B iphenyls ; PCT : P oly c hlorinated T riphenyls PBDE(聚溴二苯醚) : P oly b romo d iphenyl E thers =PBBE目前Pb使用EPA3050B規範; Cd使用EN1122規範檢驗.。