Repair Methods for Defective Insulation Sheath - Yangzhou Darui

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Wire and cable PVC insulation layer and sheath layer with local defects are allowed to be repaired, such as material breakage, pits, disconnection, wrinkles, unevenness, ears, edge folds, breakdown, joints, and other phenomena.

2. Materials and tools used

Raw materials use plastic strips, skins, blocks, and tubes of the same plastic. The raw materials should be smooth, clean, and free of other defects.

Tools used are fine wood rasps, knives, scissors, pliers, screwdrivers, copper sheets, or smooth cable paper. For plastic welding, use a hot air plastic welding gun, electric soldering iron, with a power of 300W or above.

3. Repair methods for local defects

For breakdown points, holes, pits, and other repairs, use a knife to trim the defect and cut it into a 45-degree angle slope shape. Place a plastic block of the same size on the repair area, fix it with pliers or a screwdriver, then continuously weld it with a hot air welding gun. Use a copper sheet to compact, press, and flatten it. When welding plastic, be careful not to make the hot air temperature too high to avoid burning the repaired area. After repair, test with a spark tester; it is qualified if no breakdown occurs.

Use a knife to cut the defect area of the plastic layer into a 45-degree angle slope. Take a plastic block or strip with the same shape, color, and thickness. Fix it with pliers or a screwdriver, weld it with a hot air welding gun, then use a copper sheet to compact, press, and flatten it. Finally, test with a spark tester; it is qualified if no breakdown occurs.

Scrape the plastic defect flat with a knife, fill the concave part with the same plastic strip under the action of a hot air plastic welding gun, then use a copper sheet to press, compact, and flatten the repaired area. After testing with a spark tester, it is qualified if no breakdown occurs.

4. Repair methods for large joints

1) General large joint repair: Cut both sides of the broken material along the circumference of the plastic layer into a 45-degree angle slope. Take a clean plastic tube with the same color and thickness, and with length and outer diameter matching the broken area. Cut an opening along the axis at a 45-degree angle on one side of the tube, place it over the broken area, tie it tightly with fine copper wire at equal distances, then weld it with the same plastic strip using a hot air plastic welding gun, and use a copper sheet to compact, press, and flatten. After testing with a spark tester, it is qualified if no breakdown occurs.

2) Large joint repair during production: During the production process, if there is a temporary stop due to other reasons and the sheath is disconnected, continuous jointing can be performed. The method is to cut the plastic sheath into a 45-degree angle circumferential slope, retreat to the machine head, insert it into the mold core nozzle for 30mm, then run the glue. After the glue is properly run, the crew members cooperate with each other. When starting the machine, manually connect the plastic layer, and then perform shaping and repair.

3) If quality defects occur over a longer length from one end of the cable sheath, while the other end has mostly good sheath, and the cable length is fixed, the large joint repair method during production can also be used. Just after stripping the defective sheath from one end, select a larger mold on the extruder, first extrude and wrap the stripped end according to the process, then gradually increase the traction speed at the large joint so that the sheath at the joint gradually thins and covers the original sheath cut into a slope. After coming off the machine, perform shaping and repair.







Note: The above information and technical parameters are compiled and released by Yangzhou Darui Electric Co., Ltd.