CN102056963B - 高性能耐高温电线或电缆 - Google Patents

高性能耐高温电线或电缆 Download PDF

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CN102056963B
CN102056963B CN2009801211261A CN200980121126A CN102056963B CN 102056963 B CN102056963 B CN 102056963B CN 2009801211261 A CN2009801211261 A CN 2009801211261A CN 200980121126 A CN200980121126 A CN 200980121126A CN 102056963 B CN102056963 B CN 102056963B
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安东尼奥·帕格利厄卡
安德鲁·卡斯韦尔
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Abstract

本发明提供电线或电缆，其包括芯(10)和护套，护套包括防火层(14)和缠绕的聚醚醚酮(PEEK)膜(16)，防火层(14)包括分散在聚合物基质如有机硅中的云母颗粒。可提供PEEK或另外的聚合物的外部包覆层(18)，其可被烧结以提供坚韧的外部保护覆盖层。PEEK层和云母层协同地组合以提供具有增强的阻燃性以及高的柔韧性和抗机械应力性、同时具有减小的重量和直径的护套。

Description

高性能耐高温电线或电缆
本发明涉及用在高要求或极端条件中例如用在钻井或采矿、商业或军用的航空航天和航海应用、以及机动车、铁路和公共交通运输工具(masstransport)中的高性能、耐高温和优选耐火的电线和电缆。这样的电缆可暴露于极端温度、以及腐蚀性物质或气氛、或者火中。高性能电线通常包括功能性的芯例如电导体或光纤、以及一层或多层绝缘和/或保护性包覆层。这些包覆层应该是柔韧的并且体积不太大，因为在许多情况下要求电线具有小的直径。
已知多种类型的聚合物用于电线和电缆护套中，例如聚四氟乙烯(PTFE)和聚醚醚酮(PEEK)。PTFE具有如下优点：其是非常坚韧(tough)和化学惰性的，具有高的软化点、低的摩擦系数和良好的电绝缘性质。
由于PEEK具有良好的阻燃性，是自熄性的且具有非常少的烟，因此其已经在电线和电缆护套中找到越来越多的应用。其还具有对动态切入(dynamic cut-through)和刮擦摩擦的良好的机械耐受性、以及在为薄的部件例如膜时的良好的柔韧性、良好的延伸率。然而，其对电弧径迹(arc tracking)以及对丙酮和强酸的侵蚀可为敏感的。
EP-A-572 177公开了多孔PTFE和PEEK的电绝缘层压材料。其目的是提供用于飞机机体电线绝缘的柔韧电绝缘材料，其重量轻且具有高的机械强度、耐热性和耐化学性以及减小的介电常数。
然而，仍需要耐火且耐非常高的温度的电线和电缆绝缘材料。赋予这样的阻燃性的一种方法是施加包括分散在聚合物基质中的云母颗粒(典型地为小片)的包覆层。例如，JP-A-2003100149公开了细云母粉和玻璃料在有机硅树脂中的分散体用于包覆耐火电缆的用途。然而，云母可增添成本，因此需要减少电缆护套的云母含量。例如，JP-A-2006120456寻求通过将用以赋予拉伸强度和尺寸稳定性的玻璃带与用以赋予耐热性、电性能和粘附性的有机硅带组合来避免云母的使用。
JP-A-2000011772公开了由与氢氧化铝和云母粉末混合的交联硅橡胶制造的耐火包覆层。
还需要可通过使用减小厚度的护套实现的减小直径的电线和电缆。
根据本发明，高性能耐高温电线包括芯和护套，该护套包括由聚醚醚酮(PEEK)、或者PEEK与另外的聚合物的共混物或合金制造的缠绕膜，所述共混物或合金含有至少30重量％、优选至少50重量％和更优选至少80重量％的PEEK。所述缠绕膜与包括分散在聚合物基质中的云母颗粒的层组合(combine)，所述聚合物基质例如有机硅(silicone)、基于二氧化硅的聚合物基质或聚合物硅氧烷(polymeric siloxane)。所述缠绕的PEEK膜可包括其它聚合物组分，和可与其它聚合物层组合，特别是与防火或耐火层组合。
所述具有分散于其中的云母颗粒的层优选为耐火层并且可为沿径向在所述PEEK层内部或外部的单独的层的形式。或者，其可与由PEEK带形成的膜组合。
所述耐火层可具有背衬层(backing layer)，例如，玻璃纤维支撑层或者另外的聚合物如聚烯烃的层。
在另一实施方式中，PEEK膜可包括两个PEEK层和在它们之间的云母层。所述云母层可包括颗粒的片或箔或层。其可适当地具有30～200μm、优选不超过100μm的厚度。
可提供额外的外部层以具有额外的强度、柔韧性和/或阻燃性。该外部层可例如包含聚四氟乙烯(PTFE)、聚偏氟乙烯(PVDF)、乙烯四氟乙烯(ETFE)、PEEK、聚烯烃、聚酰胺、硅氧烷聚醚酰亚胺(SILTONE)、热塑性聚醚酰亚胺如Ultem、聚酯、有机硅、聚氨酯、环氧树脂、丙烯酸类树脂、或者任意这些的共聚物或共混物或合金。该外部层可被烧结。
已经发现，PEEK膜和含有云母的膜可协同地组合以提供具有提高的阻燃性以及对机械应力(如弯曲、拉伸和磨擦)的耐受性的电线或电缆护套。这意味着可使用相对薄的膜制造具有减小的总直径的电线。根据本发明使用的PEEK带优选具有10～100μm的厚度。
上述包覆层可施加于多种不同类型的芯，特别是导电电线或电缆，例如：铜，其可涂覆有镍或锡或者镀有银；铝，典型地为包铜铝；银；或钢(steel)。为了其它目的，可使用非金属芯例如碳纤维芯或聚合物芯或陶瓷芯。电缆可为单芯或多芯的，或者可包括双绞线、多股芯或编织物(braid)。任意这些芯可涂覆有铜、镍、锡或银。
现在将参考附图描述本发明的优选实施方式，其中：
图1显示可如何通过缠绕PEEK和其它聚合物带制造根据本发明的绝缘电线；
图2是贯穿根据本发明的第一实施方式的多层包覆电线的横截面；
图3是贯穿根据本发明的第二实施方式的包覆电线的横截面；
图4是贯穿本发明的第三实施方式的横截面；和
图5是贯穿本发明的第四实施方式的横截面。
首先参考图1，多股电缆10具有通过缠绕和挤出施加到其上的三层护套，多股电缆10可例如为：未涂覆的或涂覆有镍、银或锡的铜电缆；铝电缆，其可为包铜铝电缆；钢电缆；或者非金属电缆如碳纤维、聚合物纤维或陶瓷纤维。成螺旋形地缠上第一带12，例如具有分散在其中的云母小片的有机硅第一带12，以形成第一缠绕包覆层14。然后，成螺旋形地缠上第二带15，例如聚醚醚酮第二带15，以形成第二包覆层16。最后，例如通过挤出施加另外的聚合物的外部层。
图2显示贯穿例如如对于图1所描述的其上已经施加了三层护套的电缆的横截面。直接围绕电缆20的最内层24是用以赋予阻燃性的含有云母的护套。这可例如为含有云母的有机硅带，其可用玻璃纤维和/或聚乙烯层作背衬。该层可以相同或不同厚度的单层或多层进行施加。
第二层26包括具有10～100μm厚度的聚醚醚酮(PEEK)缠绕带。PEEK可单独使用或者与其它聚合物共混或合金化，共混物或合金优选含有至少60％和更优选至少80％的PEEK。
根据本发明，外部层28是任选的，但是当使用外部层28时，其可为挤出的或缠绕的。其提供包封层以形成电缆的额外保护层。可使用上面对于该层所列出的任何聚合物、聚合物共混物或合金。例如，可烧结PTFE以提供航空航天市场所要求的卓越的耐化学性。PEEK层自身可烧结以凭其自身提供坚韧的外部层。
该实施方式中的PEEK和含有云母的聚合物的协同组合可提供具有潜在低的重量和低的总直径的耐高温耐火电线。云母可提供最高达1000℃的绝缘和耐火性，与PEEK组合提供即使在高温下也非常好的机械性质(包括抗动态切入性)、不燃烧特性和非常低的烟排放。PEEK层可烧结或熔合以凭其自身提供坚韧的外部层。
现在参考图3的实施方式，芯电缆或电线30可与图2的类似，但是护套的第一层32为由在PEEK膜或带上的单或双云母层形成的组合缠绕层。云母部件可例如包括具有或不具有聚乙烯层的云母/有机硅带。该实施方式也可包括任选的外部层34，其内容物(contents)范围可与图2的实施方式的相同。此外，可对外部层进行烧结。
在图4的实施方式中，芯40首先覆盖有内层42，内层42包括缠绕的PEEK或者PEEK与另外的聚合物的共混物或合金的膜。围绕内层42的是外部层，该外部层可通过缠绕或挤出施加并且可包括分散在聚合物如有机硅中的云母和/或氧化铝颗粒的防火层、或者用于图2和3中所示电线或电缆的外部层的任何聚合物的保护层。此外，可对该外部层进行烧结以提供坚韧的外部层。
如图5中所示，缠绕的PEEK膜54，或者缠绕的PEEK与一种或多种其它聚合物的共混物或合金的膜可用作用于各种各样的电线或电缆构造的外部保护层。该构造可包括具有另外的聚合物绝缘材料的导体、具有或不具有编织物例如双绞线或四对双绞线如Cat 7电缆的完整电缆构造。在图5中所示的实施方式中，在具有在二氧化硅等基质中的云母颗粒的防火或耐火绝缘层52的三芯电缆50周围形成PEEK外部护套(jacket)。可对PEEK外部护套进行熔合或烧结。

Claims (41)

1.包括芯和聚合物护套的电线或电缆，其中所述护套包括具有5～150μm厚度的缠绕的聚醚醚酮(PEEK)膜、或者含有至少30重量％PEEK的PEEK与另外的聚合物的聚合物共混物或合金膜，其中所述缠绕的PEEK膜与包括在聚合物基质中的云母颗粒的层组合，所述缠绕的PEEK膜包括两个PEEK层和在它们之间的云母层。
2.权利要求1的电线或电缆，其中所述缠绕的PEEK膜具有10～100μm的厚度。
3.权利要求1的电线或电缆，其中所述缠绕的PEEK膜包括含有至少50重量％PEEK的共混物或合金。
4.权利要求2的电线或电缆，其中所述缠绕的PEEK膜包括含有至少50重量％PEEK的共混物或合金。
5.权利要求3的电线或电缆，其中所述缠绕的PEEK膜包括含有至少80重量％PEEK的共混物或合金。
6.权利要求4的电线或电缆，其中所述缠绕的PEEK膜包括含有至少80重量％PEEK的共混物或合金。
7.权利要求1的电线或电缆，其中所述与PEEK膜组合的层为耐火层。
8.权利要求2的电线或电缆，其中所述与PEEK膜组合的层为耐火层。
9.权利要求3的电线或电缆，其中所述与PEEK膜组合的层为耐火层。
10.权利要求4的电线或电缆，其中所述与PEEK膜组合的层为耐火层。
11.权利要求5的电线或电缆，其中所述与PEEK膜组合的层为耐火层。
12.权利要求6的电线或电缆，其中所述与PEEK膜组合的层为耐火层。
13.权利要求7的电线或电缆，其中所述耐火层的基质包括硅橡胶、基于二氧化硅的聚合物基质或聚合物硅氧烷。
14.权利要求8的电线或电缆，其中所述耐火层的基质包括硅橡胶、基于二氧化硅的聚合物基质或聚合物硅氧烷。
15.权利要求9的电线或电缆，其中所述耐火层的基质包括硅橡胶、基于二氧化硅的聚合物基质或聚合物硅氧烷。
16.权利要求10的电线或电缆，其中所述耐火层的基质包括硅橡胶、基于二氧化硅的聚合物基质或聚合物硅氧烷。
17.权利要求11的电线或电缆，其中所述耐火层的基质包括硅橡胶、基于二氧化硅的聚合物基质或聚合物硅氧烷。
18.权利要求12的电线或电缆，其中所述耐火层的基质包括硅橡胶、基于二氧化硅的聚合物基质或聚合物硅氧烷。
19.权利要求7～18中任一项的电线或电缆，其中所述耐火层由缠绕带形成。
20.权利要求19的电线或电缆，其中所述缠绕的耐火材料带具有支撑或背衬层。
21.权利要求20的电线或电缆，其中所述缠绕的耐火材料层为玻璃纤维背衬的带。
22.权利要求7～18中任一项的电线或电缆，其中所述耐火层作为围绕所述芯的内层形成，且所述PEEK膜缠绕在所述耐火层周围。
23.权利要求19的电线或电缆，其中所述耐火层作为围绕所述芯的内层形成，且所述PEEK膜缠绕在所述耐火层周围。
24.权利要求20的电线或电缆，其中所述耐火层作为围绕所述芯的内层形成，且所述PEEK膜缠绕在所述耐火层周围。
25.权利要求21的电线或电缆，其中所述耐火层作为围绕所述芯的内层形成，且所述PEEK膜缠绕在所述耐火层周围。
26.权利要求1～18中任一项的电线或电缆，包括围绕着所述芯的PEEK膜与具有分散于其中的云母颗粒的聚合物带的组合内层。
27.权利要求19的电线或电缆，包括围绕着所述芯的PEEK膜与具有分散于其中的云母颗粒的聚合物带的组合内层。
28.权利要求20的电线或电缆，包括围绕着所述芯的PEEK膜与具有分散于其中的云母颗粒的聚合物带的组合内层。
29.权利要求21的电线或电缆，包括围绕着所述芯的PEEK膜与具有分散于其中的云母颗粒的聚合物带的组合内层。
30.权利要求22的电线或电缆，包括围绕着所述芯的PEEK膜与具有分散于其中的云母颗粒的聚合物带的组合内层。
31.权利要求23的电线或电缆，包括围绕着所述芯的PEEK膜与具有分散于其中的云母颗粒的聚合物带的组合内层。
32.权利要求24的电线或电缆，包括围绕着所述芯的PEEK膜与具有分散于其中的云母颗粒的聚合物带的组合内层。
33.权利要求25的电线或电缆，包括围绕着所述芯的PEEK膜与具有分散于其中的云母颗粒的聚合物带的组合内层。
34.权利要求26的电线或电缆，其中所述组合内层包括聚烯烃膜。
35.权利要求27的电线或电缆，其中所述组合内层包括聚烯烃膜。
36.权利要求28的电线或电缆，其中所述组合内层包括聚烯烃膜。
37.权利要求29的电线或电缆，其中所述组合内层包括聚烯烃膜。
38.权利要求30的电线或电缆，其中所述组合内层包括聚烯烃膜。
39.权利要求31的电线或电缆，其中所述组合内层包括聚烯烃膜。
40.权利要求32的电线或电缆，其中所述组合内层包括聚烯烃膜。
41.权利要求33的电线或电缆，其中所述组合内层包括聚烯烃膜。
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