CN101889316A - 耐电弧光滑电线 - Google Patents
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Abstract
本发明公开了一种电线,该电线被构造成具有导体(12)、主绝缘层(22)和次绝缘层(24)。第三绝缘层(26)施加在次绝缘层上,其中,第三绝缘层包括在电线的三个绝缘层中使用的仅有的标记添加剂。
Description
相关申请
本申请要求2007年12月7日提出的美国临时申请61/005718和2008年6月10日提出的美国临时申请61/131629的优先权,上述申请全部内容通过引用合并于此。
技术领域
本申请涉及电缆结构,更具体地说,涉及一种用于电缆的层状绝缘体。
背景技术
在高性能机身电线领域,例如应用于商用和军用飞机上,这类电线必须满足严格的性能等级。总体来说,在工业上增强电线的性能特性同时保持或减轻其重量是一个主要目标。
电线/绝缘体组合产品必须保持一些重要的性能特性,包括热机械性能、耐电弧性、紫外-激光标记能力、耐磨性、动态耐切透性(dynamiccut-through resistance)和光滑表面。
在现有技术中,包括纯聚酰亚胺绝缘带和(含氟聚合物)包覆的聚酰亚胺绝缘带的聚酰亚胺绝缘带已被当成主要的绝缘体而加以应用。聚酰亚胺具有很多有益的性能,包括良好的机械性能和绝缘性能。但是,作为绝缘带,聚酰亚胺需要被施加而不能进行熔融挤出,这是因为高分子量的聚酰亚胺由于性能参数需要造成很难被挤压。
这些聚酰亚胺绝缘带,除了它们具有的大部分优点外,在耐干和湿电弧径迹性能方面(dry and wet arc resistance tracking)较差。尽管最新的聚酰亚胺绝缘带具有含氟聚合物包覆层,从而具有改善了的电弧径迹性能,但它们仍不能理想地满足所需的耐电弧标准。
公知的,含氟聚合物(包括)具有良好的耐电弧性能,从而在用于机身用途的电线中,被广泛地应用在主绝缘层之上的第二层中。例如无熔渣的PTFE(聚四氟乙烯-)绝缘带被施加于第一聚酰亚胺绝缘体上。该结构的现有技术的电缆的一个例子,例如根据工业标准AS22759/80-82和86-92机身电线,在附图1中示出。
然而,另一个对机身电线关注点是对既需光滑又可印记(例如紫外激光印记)的追求。为了使得外部的聚四氟乙烯层可印记,添加剂尤其是二氧化钛和其它相关物质(颜料)被加入聚四氟乙烯绝缘带中。这些添加材料尽管很容易被紫外激光标记,但通常成倍地减弱电缆的其它重要性能,包括耐电弧性能。例如,常见的添加剂二氧化钛被采用,是由于它能增强含氟聚合物(聚四氟乙烯)的紫外激光标记性能(增强标记对比度),但它也擅长维持电弧,因而同时减弱了电线的耐电弧性。
在该行业中另一个期望的性能参数是表面光滑电线,其至少保持当前的AS22759/80-82和86-92性能水平(机身电缆的工业标准)。然而,由于绝缘带的结构,电线不是无棱边的和光滑的,并且,由于为了上述提到的标记目的而在PTFE中添加的添加剂,电线在耐湿电弧试验中性能不佳。这样,受到这些局限,典型的当前机身电线的规格仅要求电线分别通过“湿-电弧径迹”在中等或薄的壁厚时分别为在90%和85%。
发明内容
本发明克服了现有技术的不足,提供了一种电线,该电线具有被主绝缘层和次绝缘层包覆的导体。第三薄层施加在次绝缘层上,该第三层被设置有颜色添加剂的各种标记,从而使得外表面不仅光滑而且可标记,同时在主绝缘层和次绝缘层里则不需要添加这类添加剂。
通过将紫外激光标记和染色功能分离并局限于电线的绝缘系统的外部层,整体的绝缘系统可被设计成具有更好的机械和电性能。例如,仅在处在外面的薄的PTFE绝缘物的第三层上掺杂二氧化钛和颜色添加剂,且使次绝缘层为天然PTFE(纯的且无添加剂)。
在本发明的一种结构中,对薄的第三绝缘层的掺杂是通过熔体挤出、包裹、涂抹或以其它方式处理次绝缘层外表面以增加第三层而实现的。一个例子是将紫外激光感光剂(二氧化钛)和颜色添加剂添加到处在外面的第三绝缘层中的熔接过程。
通过将处于外面的第三绝缘层(或包覆绝缘层)和次绝缘层分开,这允许次绝缘层在制作时不添加标记添加剂,从而整个绝缘层的整体耐电弧性得以提高。事实上,纯PTFE的第二绝缘带可以做得比较薄,从而允许在形成主绝缘层时更自由,例如在所使用的绝缘带的成份方面。
更进一步,这种PTEF带来的次绝缘层的电弧径迹性能的改进使得在电线绝缘层中的整体聚酰亚胺浓度,例如第一绝缘带层的聚酰亚胺成分相对于含氟聚合物成分增加了,这样获得了更好的热和机械性能,却没有损失耐电弧性能。
这种特性使得在满足特定需求的机械特性时有更多的设计选择,同时也能满足通过必要的性能标准。例如,这种布置使得电缆能在检测等级95%或者更高时通过耐电弧测试,并满足AS22759/80-/82以及AS22759/86-/92的要求。
最后,本发明提供了一种电线,该电线具有导体、主绝缘层和次绝缘层。第三绝缘层被施加于所述次绝缘层上,这里所述第三绝缘层包括在所述电线的三个绝缘层中仅有的标记添加剂。
附图说明
本发明通过以下的文字和附图说明可更好地理解,这里:
图1是现有技术的机身电线(AS22759/80-82,86-92)
图2表示根据本发明一个实施方式的多层绝缘机身电缆;和
图3表示根据本发明另一个实施方式的多层绝缘机身电缆。
具体实施方式
在本发明的一个实施方式中,提供了一电线(或电缆)10,其具有导体芯(12)和绝缘层20。如前所述,电线10普遍应用于机身领域,但是本发明并不局限在该这方面。
在图2中所示的电线10的导体芯12是多根绞合的导体元件14。为了说明本发明的突出特征,每一导体元件14包括19股32AWG镀镍铜(19×32,20的美国电线规格NPC导体)。但是,应当理解每一单独导体元件14可用其它任何符合所需应用的导体材料制造。此外,本发明与将在下面描述的绝缘层20相关的特点是可应用在单独的实心结构(仅一个元件)的导体芯12上。
在本发明的一个实施方式中,如图2所示,绝缘层20包括第一主绝缘层22、次绝缘层24和包覆层26。
在一种布置中,主绝缘层22优选地由复合绝缘带(例如DupontTM120TW T 561)构成,其总厚度大约0.0012英寸。这样的绝缘带可由构成,在该聚酰亚胺基体的两侧上包覆有改性聚四氟乙烯。在另一布置中,用于主绝缘层的绝缘带是简单的没有包覆的聚酰亚胺绝缘带。
在本发明的一个布置中,为了形成层22,这样的一个绝缘带在导体芯12上以大约51-54%的重叠,优选为53%的重叠螺旋缠绕。在大约50%重叠时的缠绕相当于主绝缘层的厚度大约为两倍的绝缘带的厚度。对绝缘层22的这种设计被用作说明本发明的突出特色。但是,应该清楚的是,在本发明的范围中,其它将主绝缘层22施加到导体芯12的方法也可应用。
次绝缘层24优选地采用由天然的无熔渣的聚四氟乙烯构成缠绕绝缘带形成,其厚度基本上为0.0015-0.0020英寸,也可以是0.0005-0.004英寸的范围。理想地,用于次绝缘层24的绝缘带由不含添加剂的天然聚四氟乙烯构成,但是它们也可由含重量上4%或更少二氧化钛和/或10%或更少的其它添加剂的改性聚四氟乙烯构成。这种绝缘带可为成薄片的无熔渣浇注(cast)或延展(expanded)形式。尽管理想的是,为利用接下来描述的第三绝缘层26的优点,聚四氟乙烯绝缘带应不含添加剂,但是一些少量的添加剂(或可能的杂质)也不会损害本发明的有益之处。
如同形成主绝缘层22的绝缘带,这个绝缘带也是以大约51-54%重叠,优选53%的重叠螺旋缠绕在主绝缘层22上。与现有技术不同,次绝缘层不含任何添加剂例如标记添加剂,这样使整个电缆绝缘层20具有非常好的耐电弧性能。对次绝缘层24的这种设计作为代表性结构来说明本发明的突出特色。但是,和主绝缘层22一样,应该清楚在本发明的范围内,其它将次绝缘层23施加到主绝缘层22的方法也可应用。
在本发明的一个实施方式中,第三绝缘层26被施加到次绝缘层24的外面。有利的是,它可以借助于熔接来施加,其中利用表面处理并然后被熔接到次绝缘层24的外表面上来施加聚四氟乙烯。在该布置中,第三绝缘层26优选的被若干次个重复施加,每一重复优选为厚度0.0001-0.0004英寸的层。每一施加重复可以在0.00005-0.001英寸的范围内。但是,应该清楚第三绝缘层26还可有其它方式施加,例如熔体挤出、缠绕或涂抹。
熔接包覆材料(聚四氟乙烯熔接包覆层26)被设计用于给电线添加颜色,使得电线10在其表面上具有紫外激光可标记性。出于这一目的,聚四氟乙烯层可包含标记添加剂,例如二氧化钛。尽管这存在上述确定的耐电弧性能方面的缺陷,因为第三绝缘层26相对于整个次绝缘层的厚度很小而使得这个影响最小化。
此外,采用熔接包覆施加的外部包覆层或第三绝缘层26还有另外的优点,即:可以使次绝缘层(其为缠绕的聚四氟乙烯绝缘层)内的螺旋凹痕平整化,这不仅使标记更容易,还消除了棱边(由绝缘带的缠绕形成),从而增强了耐磨性,且避免了由于物理环境危害造成的绝缘带绝缘体突然被卡住或展开的情况。
在本发明的另一个实施方式中,同样采用图2来说明,主绝缘层22是由绝缘带制成,绝缘带包括聚酰亚胺基体,在聚酰亚胺基体膜的两侧都包覆了改性聚四氟乙烯。这个绝缘带然后以大约63-70%重叠,优选的65%的重叠螺旋缠绕在导体芯上。在这个布置中,主绝缘层22的绝缘带以大约为65%的重叠缠绕不仅导致主绝缘层的总厚度是绝缘带厚度的三倍,还导致更光滑轮廓的外表面。
缠绕在其上的次绝缘层24是由天然的无熔渣聚四氟乙烯绝缘带构成,厚度大约为0.0015英寸或者更小。而且,该绝缘带也是以大约65%重叠螺旋缠绕在主绝缘层22上。由于次绝缘层24是由纯聚四氟乙烯构成,不含标记添加剂,它在制作时的厚度可比正常情况小,因为它纯的不含添加剂成分的配方,可在较小厚度时可达到所需要的绝缘和机械性能。另外,以大约65%的重叠缠绕还导致更光滑轮廓的外表面。
和第一种布置相似,例如借助于上述的聚四氟乙烯熔接的方式,第三包覆层26被作为最终外层施加于主绝缘层24上。第三绝缘层26可以在若干重复过程中施加,每一个重复过程的厚度大约0.0001-0.0004英寸。
在本发明的另一实施方式中,如图2所示,电线10具有相同的导体芯12、主绝缘层22和次绝缘层24。在本实施例中,第三绝缘层(或包覆层)26是螺旋缠绕的聚四氟乙烯绝缘带,厚度为0.0015英寸,以大约10%的重叠施加。和上述的第三绝缘层26相似,这一层所用的聚四氟乙烯被设计成对电线10添加颜色,并且使电线10在其表面具有紫外激光印记性,例如通过包含二氧化钛添加剂。尽管这样会存在上述确定的耐电弧性能相关的缺陷,但因为第三绝缘层26相对于整个次绝缘层24的厚度很小,这种影响被最小化。
如图3所示,在本发明的另一个实施方式中,一个另外的中间熔接包覆层23添加到主绝缘层22和次绝缘层24之间。在这个布置中,如前面例子中的,在采用聚四氟乙烯包覆的聚酰亚胺绝缘带而形成主绝缘层22之后进行。
此后,熔接包覆层23施加于主绝缘层24上。这一内部熔接包覆层23优选的采用若干个重复步骤施加,这里每一个重复步骤的厚度优选是大约0.0001-0.0005英寸。每一次施加的重复步骤可以为0.00005-0.001英寸。内部包覆层23有利地布置为覆盖并密封主绝缘层22,同时为次绝缘层24提供光滑、无棱边表面作为基底。这增加了电缆10外表面的整体光滑性。在施加内部包覆层23之后,次绝缘层24和熔接包覆层26如上所述施加。
根据上述的实施方式,外部熔接包覆层26给电线10的设计者提供了具备合适的设计方案的机会,即允许在标记时有良好的激光对比度。电线表面的高的激光印记对比度是工业上大力追求的。通过在薄层施加的第三绝缘层26如通过熔接施加的绝缘层中添加添加剂,以及保持次绝缘层24为纯的聚四氟乙烯绝缘带,电线10能够在不损失耐湿电弧性的同时保持最大的激光对比度。第三绝缘层还使得电线10具有表面光滑性,这也是工业上所追求的性能。
将标记成分添加到薄熔接施加的第三绝缘层26,与下面的由聚四氟乙烯绝缘带制成的次绝缘层分开,使得电线10的设计者具有另外的自由度去探寻具有独特特性的新的电线设计。
例如,一个这样的性能特性是“动态切透”(dynamic cut-thru)性能电线。“动态切透”性能,被设计用于度量电缆或电线绝缘体抵抗锋利边缘切割并因此在使用状态下短路的能力,主要是由在绝缘体20中、如在主绝缘层22中存在的聚酰亚胺的量来决定。但是,聚酰亚胺材料损害电缆10的耐湿电弧性能,因而在主绝缘带和第二绝缘体上包覆聚四氟乙烯成为必要。本发明的设置,由于纯的聚四氟乙烯次绝缘层24而极大提高了湿耐电弧性能,在第一绝缘体22中的聚酰亚胺成分可以增加以增强绝缘体的机械性能(例如动态切透),同时仍满足耐湿电弧性的标准。对于当前存在的电线系统,按照AS22759/80-/82,86-/92和BMS-1360中规定的电线系统,是不可能具有这种灵活性的。
本发明的另一个优点是,将纯聚四氟乙烯的次绝缘层24和薄的第三绝缘层的设计分立,使得可在电线的第三绝缘层26中自由使用可选择的含氟聚合物,例如全氟烷氧基(PFA)、全氟甲基乙烯基醚(MFA)、乙烯四氟乙烯(ETFE)、氟化乙丙烯(FEP),以达到在保持需要的电弧径迹性能的同时达到较好的耐磨性和耐动态切透性。分立的包覆层26还允许工程师设计这样一个方案,在该层中使用纳米过滤器,但不存在该纳米过滤器脱落的问题(纳米过滤器通常成块聚集,在化合过程中难以分散),这样可以进一步提高熔接层26自身机械、热机械、燃烧性能,同时基于主绝缘层22和次绝缘层24还保持了良好的耐电弧性。
虽然在这里仅显示和描述了本发明的特定的技术特征,但是对本领域技术人员来说可进行改进、替换、变化和等同。因此需要指明本申请包含了落入本发明的实质范围的任何改进和变化形式。
Claims (17)
1.一种电线,所述电线包括:
导体;
主绝缘层;
次绝缘层;和
第三绝缘层,所述第三绝缘层施加于所述次绝缘层上,其中所述第三绝缘层包括在所述电线的三层绝缘层中使用的仅有的标识/颜色添加剂。
2.如权利要求1所述的电线,其特征在于,所述导体由多根绞合的导体元件构成。
3.如权利要求1所述的电线,其特征在于,所述主绝缘层由聚合物绝缘带构成。
4.如权利要求3所述的电线,其特征在于,所述聚合物绝缘带是具有聚酰亚胺芯部的绝缘带。
5.如权利要求4所述的电线,其特征在于,所述聚酰亚胺芯部在至少一侧上由含氟聚合物包覆。
6.如权利要求3所述的电线,其特征在于,所述主绝缘层由聚合物绝缘带构成,该聚合物绝缘带围绕所述导体以大约5-75%的重叠螺旋缠绕。
7.如权利要求1所述的电线,其特征在于,所述次绝缘层是由不含任何添加剂的纯聚四氟乙烯制成的聚合物绝缘带形成。
8.如权利要求7所述的电线,其特征在于,所述次绝缘层是由围绕所述导体以大约5-75%重叠螺旋缠绕聚合物绝缘带而构成。
9.如权利要求7所述的电线,其特征在于,所述次绝缘层是由厚度大约为0.0005-0.004英寸的聚合物绝缘带构成。
10.如权利要求1所述的电线,其特征在于,所述第三绝缘层被施加成使得所述电线的所形成的外表面光滑。
11.如权利要求1所述的电线,其特征在于,所述第三绝缘层由连续的层叠步骤形成,每一步骤施加大约0.0001-0.0004英寸的包覆层。
12.如权利要求1所述的电线,其特征在于,所述第三绝缘层由聚合物构成,该聚合物选自聚四氟乙烯、改性聚四氟乙烯、PFA、MFA、ETFE、FEP组成的组。
13.如权利要求12所述的电线,其特征在于,所述第三绝缘层进一步包括紫外激光标记添加剂。
14.如权利要求12所述的电线,其特征在于,所述第三绝缘层进一步包括颜色添加剂。
15.如权利要求1所述的电线,进一步包括中间包覆层,其位于主绝缘层和次绝缘层之间。
16.如权利要求15所述的电线,其特征在于,所述中间包覆层在多个重复步骤中施加,每一步骤大约0.0001-0.0004英寸。
17.如权利要求15所述的电线,其特征在于,所述中间包覆层由聚合物构成,该聚合物选自聚四氟乙烯、改性聚四氟乙烯、PFA、MFA、ETFE、FEP组成的组。
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US12/315,621 US20090250243A1 (en) | 2007-12-07 | 2008-12-04 | Arc resistant and smooth wire |
PCT/IB2008/055669 WO2009083934A2 (en) | 2007-12-07 | 2008-12-05 | Arc resistant and smooth wire |
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Cited By (5)
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CN104867574A (zh) * | 2015-05-08 | 2015-08-26 | 江苏通光电子线缆股份有限公司 | 一种新型拖拽航空电缆及其制备方法 |
CN106448846A (zh) * | 2016-12-12 | 2017-02-22 | 广州凯恒特种电线电缆有限公司 | 一种氟聚合物电线电缆及其制备方法 |
CN110148489A (zh) * | 2019-06-03 | 2019-08-20 | 扬州市德友线缆有限公司 | 一种宇航用轻型高导电率耐串弧耐辐照电缆及其制造工艺 |
CN111492445A (zh) * | 2017-12-20 | 2020-08-04 | 株式会社润工社 | 电缆 |
US11763962B2 (en) | 2017-12-20 | 2023-09-19 | Junkosha Inc. | Cable |
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EP2731113B1 (en) * | 2012-06-11 | 2016-06-29 | Fujikura Ltd. | Oxide superconducting wire and superconducting coil |
US10256009B2 (en) | 2014-06-19 | 2019-04-09 | Saint-Gobain Performance Plastics Corporation | Laser-markable insulation material for wire or cable assemblies |
US9881714B2 (en) | 2014-06-19 | 2018-01-30 | Saint-Gobain Performance Plastics Corporation | Laser-markable insulation material for wire or cable assemblies |
US20160055939A1 (en) * | 2014-08-19 | 2016-02-25 | Nexans | Arrangement and construction for airframe wires |
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GB1362179A (en) * | 1970-11-25 | 1974-07-30 | British Insulated Callenders | Electric cables |
CA2373524A1 (en) * | 1999-06-02 | 2000-12-07 | Tyco Electronics Corporation | Insulated electrical conductor |
DE10057657A1 (de) * | 2000-11-21 | 2002-05-29 | Eilentropp Kg | Elektrische Leitung |
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2008
- 2008-12-05 BR BRPI0819973A patent/BRPI0819973A2/pt not_active IP Right Cessation
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- 2008-12-05 CA CA2707825A patent/CA2707825A1/en not_active Abandoned
- 2008-12-05 CN CN2008801194810A patent/CN101889316A/zh active Pending
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Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
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CN104867574A (zh) * | 2015-05-08 | 2015-08-26 | 江苏通光电子线缆股份有限公司 | 一种新型拖拽航空电缆及其制备方法 |
CN106448846A (zh) * | 2016-12-12 | 2017-02-22 | 广州凯恒特种电线电缆有限公司 | 一种氟聚合物电线电缆及其制备方法 |
CN111492445A (zh) * | 2017-12-20 | 2020-08-04 | 株式会社润工社 | 电缆 |
CN111492445B (zh) * | 2017-12-20 | 2022-04-08 | 株式会社润工社 | 电缆 |
US11763962B2 (en) | 2017-12-20 | 2023-09-19 | Junkosha Inc. | Cable |
CN110148489A (zh) * | 2019-06-03 | 2019-08-20 | 扬州市德友线缆有限公司 | 一种宇航用轻型高导电率耐串弧耐辐照电缆及其制造工艺 |
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BRPI0819973A2 (pt) | 2017-06-13 |
RU2010128109A (ru) | 2012-01-20 |
CA2707825A1 (en) | 2009-07-09 |
WO2009083934A3 (en) | 2009-09-11 |
EP2220656A2 (en) | 2010-08-25 |
WO2009083934A2 (en) | 2009-07-09 |
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