CN105405491B - 一种可增容的架空绝缘电缆 - Google Patents
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Abstract
一种可增容的架空绝缘电缆属于绝缘电缆技术领域，尤其涉及一种可增容的架空绝缘电缆。本发明提供一种导电率高、防护效果好的可增容的架空绝缘电缆。本发明包括上端聚乙烯护套和下端聚乙烯护套，上端聚乙烯护套与下端聚乙烯护套之间通过竖向连接筋相连，上端聚乙烯护套尺寸及护套内容量大于下端聚乙烯护套尺寸及护套内容量，其结构要点上端聚乙烯护套内侧由内之外依次为硬铝型线绞合层、半导体层，硬铝型线绞合层由多个纵截面为等腰梯形的硬铝型线呈放射状无缝紧密交错连接构成；所述下端聚乙烯护套内侧设置有阻水层，阻水层内设置有多个松套管，松套管内设置有光纤。
Description
技术领域
本发明属于绝缘电缆技术领域，尤其涉及一种可增容的架空绝缘电缆。
背景技术
随着我国经济的的持续高速发展，对电力能源的需求也急剧增加。城市化进程的快速推进，人口的急剧增加，电力用户的增加和用电设施的多元化，使得城市配电网负荷增长迅速。多年来，虽然网省公司开展了大规模的老旧设备改造工作，但由于城市地上地下走廊资源奇缺，供需矛盾依然严重，除电力电缆外城市外环和城乡结合部还大量采用架空绝缘电缆，仅沈阳公司就1000多公里，工业重心外移，城市配电线路走廊比送电线路更为紧张，架空配电线路成为供电瓶颈，急需寻求解决办法。，因此，研制和开发增容架空绝缘导线，利用现有配电线路进行增容改造，可提高输电容量20%，能很好地解决上述问题。采用10kV绝缘型增容导线应用于配电线路建设或老旧线路增容改造，是电力行业增容改造是一个新的尝试，如果能利用原有线路路径，避免征地建设等环节，缩短施工周期，降低工程造价，将具有较好的社会效益和经济效益。
普通架空绝缘导线铝导体部分采用圆型正规同心绞合方式，虽然在生产工艺中有紧压工序，但无法使铝单线紧密的绞合在一起，它的紧压系数仅达到87-89%。普通架空绝缘导线中的铝导体均为普通电工铝，导电率为61%IACS。普通架空绝缘导线的绝缘料采用交联聚乙烯绝缘，它的最高工作温度可达到90度。
发明内容
本发明就是针对上述问题，提供一种导电率高、防护效果好的可增容的架空绝缘电缆。
为实现上述目的，本发明采用如下技术方案，本发明包括上端聚乙烯护套和下端聚乙烯护套，上端聚乙烯护套与下端聚乙烯护套之间通过竖向连接筋相连，上端聚乙烯护套尺寸及护套内容量大于下端聚乙烯护套尺寸及护套内容量，其结构要点上端聚乙烯护套内侧由内之外依次为硬铝型线绞合层、半导体层，硬铝型线绞合层由多个纵截面为等腰梯形的硬铝型线呈放射状无缝紧密交错连接构成；所述下端聚乙烯护套内侧设置有阻水层，阻水层内设置有多个松套管，松套管内设置有光纤。
作为一种优选方案，本发明所述硬铝型线绞合层采用高导电率硬铝型线绞合层。
作为另一种优选方案，本发明所述硬铝型线绞合层的纵截面为由内之外的三层结构，每层均为由多个硬铝型线按圆周排布组成纵截面为环形的结构。
作为另一种优选方案，本发明所述松套管采用PBT松套管。
作为另一种优选方案，本发明所述阻水层内还设置有缆膏、加强芯和填充条。
作为另一种优选方案，本发明所述加强芯采用FRP加强芯。
作为另一种优选方案，本发明所述松套管内填充有纤膏。
作为另一种优选方案，本发明所述硬铝型线的拉制采用了8+3高速拉丝机，硬铝绞线的绞制是在54盘框式绞线机上进行的。
其次，本发明所述上端聚乙烯护套和下端聚乙烯护套采用耐热105℃耐候化学交联聚乙烯绝缘料，耐热105℃耐候化学交联聚乙烯绝缘料是由如下重量份数的原料组成的：低密度聚乙烯100份、过氧化物交联剂1.0～3.0份、炭黑母粒1.0～6.0份、抗氧剂0.1～1.0份、成核剂0.1～1.0份。
所述低密度聚乙烯的密度为0.920±0.003 g/cm3，熔体流动指数为1.0～3.0 g/10min；
所述的过氧化物交联剂为过氧化二异丙苯（DCP）、过氧化二叔丁基（DTBP）、二-（叔丁基过氧化异丙基）苯（商品名F40）中的一种或几种。
所述的炭黑母粒为P型炭黑，含量为40%。
所述的抗氧剂为4,4'-硫代双(6-叔丁基-3-甲基苯酚)（商品名抗氧剂300#）、β-（3,5-二叔丁基-4-羟基苯基）丙酸正十八碳醇酯（商品名抗氧剂1081）、四[甲基-β-（3，5-二叔丁基-4-羟基苯基）丙酸酯]季戊四醇酯（商品名抗氧剂1010）、3,5-双（1,1-二甲基乙基）-4-羟基苯丙酸硫代二-2,1-乙二醇酯（商品名抗氧剂1035）中的一种或几种。
所述的成核剂为美利肯公司的Hyperform HPN-20E。
另外，本发明所述耐热105℃耐候化学交联聚乙烯绝缘料的制备方法，包括：将低密度聚乙烯和炭黑母粒均匀混合后，通过失重称定量加入BUSS往复式单螺杆挤出机；然后将过氧化物交联剂、抗氧剂和成核剂混合均匀后，通过液体泵定量注射加入BUSS往复式单螺杆挤出机；在120℃±10℃下混炼均匀后挤出切粒，冷却后进入沸腾干燥塔干燥，洁净包装，即得。
本发明有益效果。
本发明硬铝型线绞合层由多个纵截面为等腰梯形的硬铝型线呈放射状无缝紧密交错连接构成；用梯型线代替圆单线，且呈放射状无缝紧密交错连接构成，相互接触更加紧密，大幅度降低传输电量损耗；而且，硬铝线的导电率高，进一步降低传输电量损耗。
本发明下端聚乙烯护套内侧设置有阻水层，阻水层内设置有多个松套管；电缆防护效果好，大幅度延长电缆的使用寿命。
附图说明
下面结合附图和具体实施方式对本发明做进一步说明。本发明保护范围不仅局限于以下内容的表述。
图1是本发明结构示意图。
图中，1为FRP加强芯、2为PBT松套管、3为纤膏、4为光纤、5为连接筋、6为上端聚乙烯护套、7为半导体层、8为硬铝型线绞合层、9为缆膏、10为阻水层、11为填充条、12为下端聚乙烯护套。
具体实施方式
如图所示，本发明包括上端聚乙烯护套和下端聚乙烯护套，上端聚乙烯护套与下端聚乙烯护套之间通过竖向连接筋相连，上端聚乙烯护套尺寸及护套内容量大于下端聚乙烯护套尺寸及护套内容量，上端聚乙烯护套内侧由内之外依次为硬铝型线绞合层、半导体层，硬铝型线绞合层由多个纵截面为等腰梯形的硬铝型线呈放射状无缝紧密交错连接构成；所述下端聚乙烯护套内侧设置有阻水层，阻水层内设置有多个松套管，松套管内设置有光纤。
所述硬铝型线绞合层采用高导电率硬铝型线绞合层。可采用高导电率（63%IACS）硬铝型线绞制而成，其特点是在满足GB/T 14049-2008额定电压10kV架空绝缘电缆导体面积不变、力学性能不降低的前提下，将硬铝线的导电率由61%IACS提高到63%IACS，达到提高输送容量、降低线路损耗的目的。高导电率铝导电率为63%IACS，而普通导线的硬铝电导率为61%IACS，采用高导电率型线铝绞线比相同规格的普通铝绞线的损耗减少2%，相当于节约大量能源。
所述硬铝型线绞合层的纵截面为由内之外的三层结构，每层均为由多个硬铝型线按圆周排布组成纵截面为环形的结构。
所述松套管采用PBT松套管。
所述阻水层内还设置有缆膏、加强芯和填充条。
所述加强芯采用FRP加强芯。
所述松套管内填充有纤膏。
所述硬铝型线的拉制采用了8+3高速拉丝机，硬铝绞线的绞制是在54盘框式绞线机上进行的。
所述上端聚乙烯护套和下端聚乙烯护套采用耐热105℃耐候化学交联聚乙烯绝缘料，耐热105℃耐候化学交联聚乙烯绝缘料是由如下重量份数的原料组成的：低密度聚乙烯100份、过氧化物交联剂1.0～3.0份、炭黑母粒1.0～6.0份、抗氧剂0.1～1.0份、成核剂0.1～1.0份。
所述低密度聚乙烯的密度为0.920±0.003 g/cm3，熔体流动指数为1.0～3.0 g/10min。
所述的过氧化物交联剂为过氧化二异丙苯（DCP）、过氧化二叔丁基（DTBP）、二-（叔丁基过氧化异丙基）苯（商品名F40）中的一种或几种。
所述的炭黑母粒为P型炭黑，含量为40%。
所述的抗氧剂为4,4'-硫代双(6-叔丁基-3-甲基苯酚)（商品名抗氧剂300#）、β-（3,5-二叔丁基-4-羟基苯基）丙酸正十八碳醇酯（商品名抗氧剂1081）、四[甲基-β-（3，5-二叔丁基-4-羟基苯基）丙酸酯]季戊四醇酯（商品名抗氧剂1010）、3,5-双（1,1-二甲基乙基）-4-羟基苯丙酸硫代二-2,1-乙二醇酯（商品名抗氧剂1035）中的一种或几种。
所述的成核剂为美利肯公司的Hyperform HPN-20E。
在105℃下热老化寿命远远优于常规产品，可以满足实际需要，有效克服现有常规产品耐热90℃的不足。本发明提供的耐热105℃耐候化学交联聚乙烯绝缘料，具有耐高温热老化性能好、耐日光老化性能好、绝缘性能佳等特点。
所述耐热105℃耐候化学交联聚乙烯绝缘料的制备方法，包括：将低密度聚乙烯和炭黑母粒均匀混合后，通过失重称定量加入BUSS往复式单螺杆挤出机；然后将过氧化物交联剂、抗氧剂和成核剂混合均匀后，通过液体泵定量注射加入BUSS往复式单螺杆挤出机；在120℃±10℃下混炼均匀后挤出切粒，冷却后进入沸腾干燥塔干燥，洁净包装，即得。
实施例1。
本实施例提供一种耐热105℃耐候化学交联聚乙烯绝缘料，是由如下重量份数的原料组成的：低密度聚乙烯（LDPE）100份、过氧化二异丙苯（DCP） 2.5份、P型炭黑母粒5.0份、3,5-双（1,1-二甲基乙基）-4-羟基苯丙酸硫代二-2,1-乙二醇酯（商品名：抗氧剂1035）0.5份、Hyperform HPN-20E 0.2份。
所述低密度聚乙烯的密度为0.920g/cm3，熔体流动指数为2.0 g/10min。
本实施例还提供一种耐热105℃耐候化学交联聚乙烯绝缘料的制备方法：按配方将LDPE、过氧化物交联剂DCP、P型炭黑母粒、抗氧剂1035和成核剂Hyperform HPN-20E，通过计量装置分别同时加入BUSS往复式单螺杆共混造粒机组，水冷，干燥，打包，即得耐热105℃架空电缆用黑色过氧化物交联聚乙烯绝缘料。
实施例2。
本实施例提供一种耐热105℃耐候化学交联聚乙烯绝缘料，是由如下重量份数的原料组成的：低密度聚乙烯（LDPE）100份、二-（叔丁基过氧化异丙基）苯（商品名：F40） 2.2份、P型炭黑母粒4.0份、β-（3,5-二叔丁基-4-羟基苯基）丙酸正十八碳醇酯（商品名：抗氧剂1081） 0.4份、Hyperform HPN-20E 0.1份。
所述低密度聚乙烯的密度为0.918 g/cm3、熔体流动指数为2.2 g/10min。
本实施例还提供一种耐热105℃耐候化学交联聚乙烯绝缘料的制备方法：将LDPE、F40、P型炭黑母粒、抗氧剂1081和成核剂Hyperform HPN-20E，通过计量装置精确的加入BUSS往复式单螺杆共混造粒机组，水冷，干燥，打包，即得耐热105℃架空电缆用黑色过氧化物交联聚乙烯绝缘料。
以上两个实施例制备的耐热105℃耐候化学交联聚乙烯绝缘料，采用GB/T 14049-2008和JB/T 10437-2004标准进行检测，测试结果见表1。
表1：两个实施例制备的绝缘料性能测试结果。
| 测试项目 | 标准值 | 实施例1 | 实施例2 |
| 老化前拉伸强度MPa | ≥14.5 | 25.8 | 26.4 |
| 老化前断裂伸长率% | ≥400 | 536 | 528 |
| 热延伸%（200℃·15min） | ≤100 | 44 | 36 |
| 交联度% | ≥80 | 86 | 87 |
| 20℃体积电阻率（Ω·m） | - | 1.2×1014 | 2.2×1014 |
| 介电强度MV/m | ≥35 | 38 | 40 |
| 介电常数（50Hz，20℃） | ≤2.35 | 2.30 | 2.28 |
| 损耗因数（50Hz，20℃） | ≤10×10-4 | 4.0×10-4 | 3.5×10-4 |
| 热老化（150℃·168 h）拉伸强度变化率% | ≤±20 | 6.7 | 9.1 |
| 热老化（150℃·168 h）断裂伸长率变化率% | ≤±20 | -9.5 | -8.2 |
| 冲击脆化温度℃ | -76 | 通过 | 通过 |
| 光老化性能42天老化后拉伸强度变化率% | ±30 | -12.1 | -7.9 |
| 光老化性能42天老化后断裂伸长率变化率% | ±30 | 8.8 | 6.4 |
由表1可知，本发明制备的耐热105℃耐候化学交联聚乙烯绝缘料，具有耐高温热老化性能好、耐日光老化性能好、绝缘性能佳等特点。
可以理解的是，以上关于本发明的具体描述，仅用于说明本发明而并非受限于本发明实施例所描述的技术方案，本领域的普通技术人员应当理解，仍然可以对本发明进行修改或等同替换，以达到相同的技术效果；只要满足使用需要，都在本发明的保护范围之内。
Claims (7)
1.一种可增容的架空绝缘电缆，包括上端聚乙烯护套和下端聚乙烯护套，上端聚乙烯护套与下端聚乙烯护套之间通过竖向连接筋相连，上端聚乙烯护套尺寸及护套内容量大于下端聚乙烯护套尺寸及护套内容量，其特征在于上端聚乙烯护套内侧由内之外依次为硬铝型线绞合层、半导体层，硬铝型线绞合层由多个纵截面为等腰梯形的硬铝型线呈放射状无缝紧密交错连接构成；所述下端聚乙烯护套内侧设置有阻水层，阻水层内设置有多个松套管，松套管内设置有光纤；
所述上端聚乙烯护套和下端聚乙烯护套采用耐热105℃耐候化学交联聚乙烯绝缘料，耐热105℃耐候化学交联聚乙烯绝缘料是由如下重量份数的原料组成的：低密度聚乙烯100份、过氧化二异丙苯（DCP）2.5份、P型炭黑母粒5.0份、抗氧剂1035 0.5份、成核剂HyperformHPN-20E 0.2份；
所述低密度聚乙烯的密度为0.920g/cm3，熔体流动指数为2.0g/10min；
所述的炭黑母粒为P型炭黑，含量为40%；
所述耐热105℃耐候化学交联聚乙烯绝缘料的制备方法，按配方将LDPE、过氧化物交联剂DCP、P型炭黑母粒、抗氧剂1035和成核剂HyperformHPN-20E，通过计量装置分别同时加入BUSS往复式单螺杆共混造粒机组，水冷，干燥，打包，即得耐热105℃架空电缆用黑色过氧化物交联聚乙烯绝缘料；
将低密度聚乙烯和炭黑母粒均匀混合后，通过失重称定量加入BUSS往复式单螺杆挤出机；然后将过氧化物交联剂、抗氧剂1035和成核剂混合均匀后，通过液体泵定量注射加入BUSS往复式单螺杆挤出机；在120℃±10℃下混炼均匀后挤出切粒，冷却后进入沸腾干燥塔干燥，洁净包装，即得。
2.根据权利要求1所述一种可增容的架空绝缘电缆，其特征在于所述硬铝型线绞合层的纵截面为由内之外的三层结构，每层均为由多个硬铝型线按圆周排布组成纵截面为环形的结构。
3.根据权利要求1所述一种可增容的架空绝缘电缆，其特征在于所述松套管采用PBT松套管。
4.根据权利要求1所述一种可增容的架空绝缘电缆，其特征在于所述阻水层内还设置有缆膏、加强芯和填充条。
5.根据权利要求4所述一种可增容的架空绝缘电缆，其特征在于所述加强芯采用FRP加强芯。
6.根据权利要求1所述一种可增容的架空绝缘电缆，其特征在于所述松套管内填充有纤膏。
7.根据权利要求2所述一种可增容的架空绝缘电缆，其特征在于所述硬铝型线的拉制采用了8+3高速拉丝机，硬铝型线的绞制是在54盘框式绞线机上进行的。
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