CN104672691A - 一种发泡聚氯乙烯电缆 - Google Patents

一种发泡聚氯乙烯电缆 Download PDF

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CN104672691A
CN104672691A CN201310630164.8A CN201310630164A CN104672691A CN 104672691 A CN104672691 A CN 104672691A CN 201310630164 A CN201310630164 A CN 201310630164A CN 104672691 A CN104672691 A CN 104672691A
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polyvinyl chloride
foamed polyvinyl
cable
foamed
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吴芳芳
段春来
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SHANGHAI KAIBO SPECIAL CABLE MATERIAL FACTORY CO Ltd
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Abstract

本发明涉及一种发泡聚氯乙烯电缆，其外包覆结构中至少一层为发泡聚氯乙烯材料；用价格低廉的发泡聚氯乙烯代替聚乙烯材料等其他高分子材料，制备发泡聚氯乙烯电缆，可以有效的降低企业的运营成本；且制备的发泡聚氯乙烯具有良好的柔韧性和抗开裂性，有利于进行电缆的敷设和维护。

Description

一种发泡聚氯乙烯电缆
技术领域
本发明涉及一种发泡聚氯乙烯电缆，属于电线电缆领域。
背景技术
电线电缆行业作为国民经济支柱行业之一的电力行业的配套行业，在国民经济中具有极其重要的作用和地位。
电线电缆产品因其具有输送能源，传递信息，沟通世界的特殊作用，被称作是国民经济的血管和神经。随着改革开发的进一步深入以及新型城镇化的逐步推进，我国在电线电缆方面的需求量将保持较高的增长。但是面对日趋激烈的竞争，如何在保证电线电缆产品的质量和性能前提下，同时有效的降低成本，节约企业资金，提高企业竞争力，成为电线电缆行业的一个重要课题。
发泡电缆因其可以有效的节约材料的用量成为众多企业的一个重要选择。发泡电缆所选择最广泛的发泡基础材料为聚乙烯，但是随着石油资源的逐渐枯竭，聚乙烯的生产成本不断增加，给企业造成了越来越多的成本压力，因此有必要去寻找既经济又实惠的发泡基础材料用于制备发泡电缆，以有效降低企业运行成本，提高竞争力。
发明内容
本发明的目的在于克服现有技术的缺陷，提供一种聚氯乙烯电缆，利用廉价易得的发泡聚氯乙烯替代聚乙烯，同时使得制得的聚氯乙烯电缆具有表面光滑，且良好的电气性能，易加工性，化学稳定性和力学性能等特点。
本发明是通过以下技术方案实现的：
一种发泡聚氯乙烯电缆，其外包覆结构中至少一层为发泡聚氯乙烯材料。
所述外包覆结构即包覆在金属线芯外的保护层；所述外包覆结构可以是绝缘层，或绝缘层和护套层，但又不限于以上二种包覆结构。
所述发泡聚氯乙烯电缆可以为单芯电缆或多芯电缆。
优选的，所述发泡聚氯乙烯电缆的制备可以通过挤压式加工、挤管式加工或半挤管式加工方法将发泡聚氯乙烯材料挤包到电缆中。
优选的，所述通过挤压式加工方法将发泡聚氯乙烯挤包到电缆中的过程，温度设置为140-170℃。
优选的，所述通过挤管式加工方法将发泡聚氯乙烯挤包到电缆中的过程，温度设置为135-160℃。
优选的，所述通过半挤管式加工方法将发泡聚氯乙烯挤包到电缆中的过程，温度设置为135-165℃。
优选的，所述发泡聚氯乙烯材料包括以下重量份的组分：
一般常用聚氯乙烯均可用于本发明，如US-70。
优选的，所述稳定剂选自金属皂类、有机锡稳定剂、环氧化合物类稳定剂、液体复合热稳定剂、有机磷酸酯类稳定剂等。
更优选的，所述稳定剂选自CZ-200，CZ-515，CZ-300，CZ-510。
优选的，所述发泡剂选自选自物理发泡剂或者是化学发泡剂。
更优选的，所述发泡剂选自氟利昂，戊烷，AC600等。
优选的，所述填充剂选自碳酸钙、二氧化硅、炭黑、二氧化钛、滑石粉、高岭土、硅灰石、蒙脱土、云母粉等。
优选的，所述润滑剂选自脂肪酸及其酯类、硬脂酸盐类、烃类等。
更优选的，所述润滑剂选自聚乙烯蜡，硬脂酸钙，硬脂酸钡，硬脂酸等。
优选的，所述增塑剂选自邻苯二甲酸类、脂肪酸二元酸酯类、磷酸酯类、环氧酯类、聚酯类、烷基磺酸苯酯类、多元醇酯类、偏苯二酸酯类等。
更优选的，所述增塑剂选自对苯二甲酸二辛酯（DOTP），H90，邻苯二甲酸二辛酯（DOP），邻苯二甲酸二异癸酯（DPHP），偏苯三酸三异辛酯（TOTM）等。
优选的，所述抗氧剂选自双酚A，抗氧剂1010，抗氧剂168等。
优选的，所述发泡聚氯乙烯的发泡程度为10-100%，优选为10-50%。
一种所述发泡聚氯乙烯材料的制备方法，包括以下步骤：
（1）将聚氯乙烯、增塑剂、稳定剂、润滑剂、发泡剂、抗氧剂和填充剂在高速混合机中进行混合；
（2）使用双螺杆挤出造粒机塑化造粒即得。
优选的，步骤（1）所述高速混合机的混合温度为25～50℃，混合时间5～15min。
优选的，步骤（2）所述双螺杆挤出造粒机的温度设置为：机筒一区135～145℃，机筒二区140～150℃，机筒三区145～155℃，机筒四区150～160℃，机筒五区150～160℃，机头和模具160～170℃。
本发明的技术效果及优点在于：通过使用成本低廉，性能良好的聚氯乙烯作为发泡电缆的发泡基础材料替代价格更昂贵的聚乙烯等其他高分子材料，制备发泡聚氯乙烯电缆，可以有效的降低企业的运营成本，显著的提高企业的竞争力和市场效益；制备的发泡聚氯乙烯电缆相比与发泡聚乙烯电缆具有加工温度低，节约企业用电成本，加工方法简单可行，适用于多种加工设备，有利于企业进行工业化大规模生产，良好的柔韧性和抗开裂性能有利于进行电缆的敷设和维护等特点。
附图说明
图1一种单芯发泡聚氯乙烯电缆截面示意图
图2一种3线芯发泡聚氯乙烯电缆截面示意图
图3一种2线芯发泡聚氯乙烯电缆截面示意图
附图标记：
1、金属线芯；
2、绝缘层；
3、护套层。
具体实施方式
以下通过特定的具体实例说明本发明的技术方案。应理解，本发明提到的一个或多个方法步骤并不排斥在所述组合步骤前后还存在其他方法步骤或在这些明确提到的步骤之间还可以插入其他方法步骤；还应理解，这些实施例仅用于说明本发明而不用于限制本发明的范围。而且，除非另有说明，各方法步骤的编号仅为鉴别各方法步骤的便利工具，而非为限制各方法步骤的排列次序或限定本发明可实施的范围，其相对关系的改变或调整，在无实质变更技术内容的情况下，当亦视为本发明可实施的范畴。
实施例1
制备单线芯的发泡聚氯乙烯电缆，截面如图1所示，包括金属线芯1，挤包在金属线芯1表面的包覆层2，包覆层2为发泡聚氯乙烯材料；
其中，所述发泡聚氯乙烯材料包括以下重量份的组分：
所述发泡聚氯乙烯材料的制备过程为：（1）按配比称取各组分；（2）将聚氯乙烯、稳定剂、发泡剂、填充剂、润滑剂，抗氧剂和增塑剂在高速混合机中30℃条件下混合0.2小时；（3）使用双螺杆挤出造粒机塑化造粒（机筒一区135～145℃，机筒二区140～150℃，机筒三区145～155℃，机筒四区150～160℃，机筒五区150～160℃，机头和模具160～170℃），即得到发泡聚氯乙烯材料。
所述包覆层2的挤包过程为：将制得的发泡聚氯乙烯电缆料通过挤压式加工方法挤包到金属线芯1上，其加工的工艺温度是140-170℃；即制得单线芯的发泡聚氯乙烯电缆。
用上述相同挤包方法制备单线芯的聚乙烯电缆，作为对比例1；
通过以上方法过程制得的单线芯发泡聚氯乙烯电缆性能测试结果如表1所示。
实施例2
制备3线芯的发泡聚氯乙烯电缆，截面如图2所示，包括金属线芯1，挤包在金属线芯1表面的绝缘层2和护套层3，绝缘层2为聚乙烯材料制备而成，护套层2由发泡聚氯乙烯材料制备而成。
所述发泡聚氯乙烯材料包括以下重量份的组分：
所述发泡聚氯乙烯材料的制备过程为：（1）按配比称取各组分；（2）将聚氯乙烯、稳定剂、发泡剂、填充剂、润滑剂和增塑剂在高速混合机中30℃条件下混合0.2小时；（3）使用双螺杆挤出造粒机塑化造粒（机筒一区135～145℃，机筒二区140～150℃，机筒三区145～155℃，机筒四区150～160℃，机筒五区150～160℃，机头和模具160～170℃），即得到发泡聚氯乙烯材料。
本实施例发泡聚氯乙烯电缆的挤包方法的操作过程为：将聚乙烯绝缘料通过挤压式加工方法挤包到金属线芯1上；将发泡聚氯乙烯材料通过挤管式加工方法挤包到聚乙烯绝缘电缆上，其加工的工艺温度是135-160℃。
用上述相同方法制备绝缘层和护套层均为聚乙烯材料的3线芯聚乙烯电缆，作为对比例2；
通过以上方法过程制得的3线芯发泡聚氯乙烯电缆性能测试结果如表1所示。
表1实施例1-2及对比例1-2制备电缆性能测试结果
序号 试验项目 单位 实施例1 对比例1 实施例2 对比例2
1 拉伸强度 MPa 14 13 17 15
2 断裂伸长率 % 200 300 260 350
3 热老化100±2℃×168h
老化后拉伸强度 MPa 12 11 15 13
拉伸强度变化率 % -15 -15 -12 -13
老化后断裂伸长率 % 180 250 230 300
断裂伸长率变化率 % -20 -17 -12 -14
4 邵氏硬度 A 83 93 85 95
5 发泡度 % 28 28 22 22
6 耐环境应力开裂 h 900 550 950 570
实施例3
制备2线芯的发泡聚氯乙烯电缆，截面如图3所示，包括金属线芯1，挤包在金属线芯1表面的包覆层2和护套层3，包覆层2为发泡聚氯乙烯材料制备而成，护套层3由发泡聚氯乙烯材料制备而成。
所述发泡聚氯乙烯材料包括以下重量份的组分：
所述发泡聚氯乙烯材料的制备过程为：（1）按配比称取各组分；（2）将聚氯乙烯、稳定剂、发泡剂、填充剂、润滑剂和增塑剂在高速混合机中30℃条件下混合0.2小时；（3）使用双螺杆挤出造粒机塑化造粒（机筒一区135～145℃，机筒二区140～150℃，机筒三区145～155℃，机筒四区150～160℃，机筒五区150～160℃，机头和模具160～170℃），即得到发泡聚氯乙烯材料。
本实施例发泡聚氯乙烯电缆的挤包方法的操作过程为：将发泡聚氯乙烯材料料通过挤压式加工方法挤包到金属线芯上；将发泡聚氯乙烯材料通过半挤管式加工方法挤包到包覆层2上，其加工的工艺温度是135-165℃。
用上述相同方法制备绝缘层和护套层均为聚乙烯材料的2线芯聚乙烯电缆，作为对比例3；
通过以上方法过程制得的2线芯发泡聚氯乙烯电缆性能测试结果如表2所示。表2实施例3和对比例3制备的电缆性能测试结果
序号 试验项目 单位 实施例3 对比例3
1 拉伸强度 MPa 13 14
2 断裂伸长率 % 200 300
3 热老化100±2℃×168h
老化后拉伸强度 MPa 11 12
拉伸强度变化率 % -15 -15
老化后断裂伸长率 % 180 260
断裂伸长率变化率 % -20 -14
4 邵氏硬度 A 81 92
5 发泡度 % 30 30
6 耐环境应力开裂 h 950 600

Claims (16)

1.一种发泡聚氯乙烯电缆，其外包覆结构中至少一层为发泡聚氯乙烯材料。
2.如权利要求1所述的发泡聚氯乙烯电缆，其特征在于，所述包覆层为绝缘层或绝缘层和护套层。
3.如权利要求1所述的发泡聚氯乙烯电缆，其特征在于，所述发泡聚氯乙烯电缆为单芯电缆或多芯电缆。
4.如权利要求1所述的发泡聚氯乙烯电缆，其特征在于，所述发泡聚氯乙烯电缆的制备通过挤压式加工、挤管式加工或半挤管式加工方法将发泡聚氯乙烯材料挤包到电缆中。
5.如权利要求4所述的发泡聚氯乙烯电缆，其特征在于，所述挤压式加工的温度为140-170℃；所述挤管式加工的温度为135-160℃；所述半挤管式加工的温度为135-165℃。
6.如权利要求1所述的发泡聚氯乙烯电缆，其特征在于，所述发泡聚氯乙烯材料的发泡程度为10-100%。
7.如权利要求1所述的发泡聚氯乙烯电缆，其特征在于，所述发泡聚氯乙烯材料包括以下重量份的组分：
8.如权利要求7所述的发泡聚氯乙烯电缆，其特征在于，所述稳定剂选自金属皂类、有机锡稳定剂、环氧化合物类稳定剂、液体复合热稳定剂和有机磷酸酯类稳定剂。
9.如权利要求7所述的发泡聚氯乙烯电缆，其特征在于，所述发泡剂选自物理发泡剂或者是化学发泡剂。
10.如权利要求7所述的发泡聚氯乙烯电缆，其特征在于，所述填充剂选自自碳酸钙、二氧化硅、炭黑、二氧化钛、滑石粉、高岭土、硅灰石、蒙脱土和云母粉。
11.如权利要求7所述的发泡聚氯乙烯电缆，其特征在于，所述润滑剂选自脂肪酸及其酯类、硬脂酸盐类和烃类。
12.如权利要求7所述的发泡聚氯乙烯电缆，其特征在于，所述增塑剂选自邻苯二甲酸类、脂肪酸二元酸酯类、磷酸酯类、环氧酯类、聚酯类、烷基磺酸苯酯类、多元醇酯类和偏苯二酸酯类。
13.如权利要求7所述的发泡聚氯乙烯电缆，其特征在于，所述抗氧剂选自双酚A、抗氧剂1010和抗氧剂168。
14.如权利要求7所述的发泡聚氯乙烯电缆，其特征在于，所述发泡聚氯乙烯材料由包括以下步骤的制备方法制备：
（1）将聚氯乙烯、增塑剂、稳定剂、润滑剂、发泡剂、抗氧剂和填充剂在高速混合机中进行混合；
（2）使用双螺杆挤出造粒机塑化造粒即得。
15.如权利要求14所述的发泡聚氯乙烯电缆，其特征在于，步骤（1）所述高速混合机混合的混合温度25～50℃，混合时间5～15min。
16.如权利要求14所述的发泡聚氯乙烯电缆，其特征在于，步骤（2）所述双螺杆挤出造粒机的温度设置为：机筒一区135～145℃，机筒二区140～150℃，机筒三区145～155℃，机筒四区150～160℃，机筒五区150～160℃，机头和模具160～170℃。
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