PTFE Cable Extrusion Line

PTFE Cable Extrusion Line

The PTFE high-temperature cable extrusion production line is a specialized equipment system dedicated to manufacturing polytetrafluoroethylene (PTFE) insulated cables. Known as the "King of Plastics," PTFE exhibits exceptional high-temperature resistance (-200°C to +260°C), outstanding chemical inertness (resisting almost all strong acids and bases), extremely low dielectric loss (making it the preferred choice for high-frequency signal transmission), and inherent flame retardancy. Through its unique paste extrusion process and high-temperature sintering technology, this production line forms a dense and uniform PTFE insulation layer on the conductor surface, making it suitable for extreme environments such as ultra-high temperatures, strong corrosion, and high-frequency communication.
Core Value:
Ensures safe cable operation in ultra-high-temperature environments (e.g., aircraft engine compartments, chemical reaction vessels);
Meets stringent requirements for signal integrity in 5G/6G high-frequency communication and millimeter-wave transmission;
Guarantees limit demands for material purity in semiconductors, medical fields, and other critical industries through a zero-defect process.

Components

A complete PTFE high-temperature cable extrusion production line typically consists of the following key units connected in series:
Unwinding Pay-Off
Used to hold and unwind the metal conductor (copper wire) spool, providing stable and controllable tension to prevent wire thinning or breakage.
Pre-Heater
Preheats the conductor before it enters the cross-head. This helps remove moisture and oil contamination from the conductor surface and raises its temperature, promoting better adhesion between the molten Teflon material and the conductor, reducing internal stress, and improving product quality.
High-Temperature Extruder
Heats and melts thermoplastic Teflon pellets (e.g., FEP/PFA), then compresses, plasticizes, and conveys them to the cross-head via the rotation of the screw.
Features:
High-Temperature Design: The barrel and screw must be made from special alloys (e.g., Inconel) to withstand the high-temperature processing environment of 380°C - 420°C.
Precision Temperature Control: The barrel is divided into multiple zones, each independently and precisely controlled by a PID system to ensure uniform and stable melting of the material.
Screw Design: Features a large length-to-diameter ratio (L/D), providing excellent plasticizing capability and stability.
Extrusion Cross-Head and Die
Guides the molten Teflon to uniformly and concentrically coat the continuously passing conductor.
Cooling Water Tank
Immerses the wire with the newly applied molten insulation layer into cooling water to rapidly solidify and set its shape. The water temperature usually requires constant control to ensure stable product performance.
Laser Diameter Gauge
Monitors the outer diameter of the insulation layer in real time and feeds the data back to the capstan or extruder speed control system, enabling closed-loop control to ensure extremely stable outer diameter tolerance.
High-Voltage Spark Tester
Applies thousands of volts of high voltage to the wire. Any pinholes or defects in the insulation layer will cause a breakdown and immediate alarm, ensuring 100% defect-free products.
Eccentricity Gauge
Detects whether the insulation layer is applied uniformly and checks for concentricity.
Capitstan / Puller: Provides smooth pulling force to draw the cable from the unwinding end through the entire production line to the take-up end. Its speed must be precisely synchronized with the extrusion speed, directly affecting the thickness and uniformity of the insulation layer.
Take-Up Spool
Winds the finished wire neatly onto a spool. The take-up tension must remain constant to avoid damaging the wire or causing loose winding.
Control System
Integrates a PLC (Programmable Logic Controller) and a touchscreen HMI (Human-Machine Interface) to centrally control all parameters of the entire production line (speed, temperature, tension, etc.), enabling automated production, data recording, and fault diagnosis.

Process Flow

Pay off -> Conductor Preheating -> High-Temperature Melt Extrusion & Coating -> Water Cooling & Setting -> Online Diameter Measurement & Spark Testing -> Pulling -> Take-Up.

PTFE Cable Extrusion Line Datasheet

Model	30	35	45	65	90
Screw Diameter (mm)	φ30	φ35	φ45	φ65	φ90
Screw L/D Ratio	25:1	25:1	25:1	25:1	25:1
Temperature Control	6 segment	6 segment	6 segment	7 segment	9 segment
Extrusion Amount (kg/hr)	15	20	25	45	70
Outlet Wire (mm)	0.25-2.5	0.6-3.0	0.8-5.0	2.0-10.0	8.0-50.0
Total Power (KW)	30	32	40	55	/

PTFE Cable Extrusion Line Application

The PTFE high-temperature cable extrusion production line is the "crown technology" for cutting-edge cable manufacturing, and its process complexity far exceeds conventional plastic extrusion. The produced cables are irreplaceable in ultra-high temperature, high frequency, and highly corrosive environments, making them a "strategic material" in fields such as aerospace, high-frequency communication, and semiconductors. It is mainly used for:
Aerospace
Wiring systems inside aircraft, satellites, and rockets, requiring extreme lightness, resistance to high and low temperatures, and flame retardancy.
Communication Technology
5G base station antenna feeders, high-frequency coaxial cables, and RF cables. Teflon’s extremely low dielectric loss is critical here.
Medical Equipment
Cables for medical imaging devices (CT, MRI), surgical instruments, and in-vivo diagnostic equipment, requiring non-toxicity, resistance to repeated sterilization (high temperature, gamma radiation), and high reliability.
Semiconductor Manufacturing
Used in chip manufacturing equipment to connect sensors and control systems in high-temperature and highly corrosive environments.
Automotive and New Energy
High-temperature wiring harnesses for new energy vehicles (inside battery packs, motor connections) and charging pile cables.
Military and Defense
High-reliability cables for radar systems, missile guidance systems, and military communication equipment.
Industrial Sector
Sensor wires, heater lead wires, and robot wiring harnesses used in high-temperature environments.