Based on our previous discussion of PTFE conductor repair and lifespan extension under the extreme 260℃ operating conditions of hot runner systems, the cold-press repair process using three layers of fluoroplastic heat shrink tubing is the most suitable solution for this condition. It completely avoids the heat damage risks of direct welding, maximizing operational reliability at high temperatures.
Core Connection Treatment: After aligning the broken cores, fully press them together with tinned copper cold-press terminals of the appropriate diameter. After crimping, trim all exposed core burrs to prevent localized overheating caused by loose connections.
Three-Layer Insulation Protection: The first layer completely wraps the core joint with ultra-thin fluoroplastic heat shrink tubing with a temperature resistance of ≥300℃. The second layer uses thickened fluoroplastic heat shrink tubing of the same specification. The third layer is reinforced with high-temperature resistant PTFE insulating tape, forming a triple redundant insulation barrier.
Installation Location Optimization: The repaired contact is moved to a low-temperature area away from the hot runner heating coil, and a high-temperature resistant insulating gasket is placed underneath to reduce the actual operating temperature of the contact and minimize continuous high-temperature impact.
High-Temperature Performance Verification: After repair, the insulation resistance is retested after being kept at 260℃ for 30 minutes. Only after confirming a value ≥100MΩ and no significant attenuation can the wire be put into use.
This process allows the repaired wire to operate stably at 260℃ for 8-12 months, far exceeding the lifespan of conventional repair methods.
