CN106601356A - 一种耐高温电线及相应的复合前驱体陶瓷带的制备方法 - Google Patents

一种耐高温电线及相应的复合前驱体陶瓷带的制备方法 Download PDF

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CN106601356A
CN106601356A CN201611193634.9A CN201611193634A CN106601356A CN 106601356 A CN106601356 A CN 106601356A CN 201611193634 A CN201611193634 A CN 201611193634A CN 106601356 A CN106601356 A CN 106601356A
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范雷方
沈刚
吴振江
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GUANGZHOU MINGXING CABLE Co.,Ltd.
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Abstract

本发明涉及一种耐高温电线及相应的复合前驱体陶瓷带制造方法。与现有技术相比，根据本发明实施例的制造方法，采用CuO、B2O3、LiF、La2O3、SrTiO3、Al2O3、酒精、丁酮、聚乙烯醇缩丁醛、邻苯二甲酸二丁酯、聚乙二醇等制备、正丁醇和乙二醇等制造复合前驱体陶瓷带，将复合前驱体陶瓷带绕包在金属导体上，并在外层包覆聚酰胺酰亚胺绝缘层。根据本发明实施例的耐高温电线具有显著的耐高温性能，使电线应用更安全。

Description

一种耐高温电线及相应的复合前驱体陶瓷带的制备方法
技术领域
本发明属于输配电线路器材领域，涉及一种电线及相应的复合前驱体陶瓷带的制备方法，尤其涉及一种耐高温电线及相应的复合前驱体陶瓷带的制备方法。
背景技术
电磁线主要分为漆包线和绕包线两大类，随着高压电机、特种电机和电器的发展，用聚酯薄膜、云母薄膜复合带等各种薄膜绝缘带制造的绕包线日益增多。有机绝缘材料在长时间的通电状态下，易发生老化。云母薄膜复合带实际是以云母材料通过粘接剂涂覆在绕包有机载体上，在高温状态下同样易老化脱离，且制造成本昂贵，加工不便。
发明内容
为了克服现有技术的不足，本发明旨在提供一种耐高温电线及相应的复合前驱体陶瓷带的制造方法。
根据本发明的一方面，一种耐高温电线由金属导体、前驱体陶瓷层、外绝缘层组成；所述金属导体为退火圆铜线或铜包铝线；所述前驱体陶瓷层由绕包在金属导体外的复合前驱体陶瓷带构成，所述陶瓷带由按重量百分比的以下成分制成：CuO 1％-5％、B2O30.3％-8.85％，LiF 0.15％-6.9％，La2O3 0.1％-1.2％，SrTiO3 2％-18％，其余为Al2O3；所述外绝缘层为聚酰胺酰亚胺薄膜层。
根据本发明的示例性实施例，所述陶瓷带的厚度为100μm-1mm；所述陶瓷带吸水率为0，常温下其介电强度≥25KV/mm，体积电阻率≥3×1015Ω·cm，抗拉强度为8Mpa-15Mpa，延伸率为6.05％-12.9％；所述陶瓷带烧蚀后形成的陶瓷的介电强度≥50KV/mm，体积电阻率≥3×1018Ω·cm。
根据本发明的另一方面，一种复合前驱体陶瓷带的制造方法，包括：
步骤一：粉体配料
按重量百分比将以下粉体进行配料：CuO 1％-5％、B2O3 0.3％-8.85％，LiF0.15％-6.9％，La2O3 0.1％-1.2％，SrTiO3 2％-18％，其余为Al2O3，经充分搅拌，得到混合粉体，其中混合粉体的粒径为1μm-10μm；
步骤二：第一次超声分散处理
对混合粉体进行第一次超声分散处理，处理时间为20min；
步骤三：第一次球磨处理
采用95％纯度的工业酒精溶剂和丁酮按重量比3:1形成的二元共沸物作为溶剂，采用蓖麻油作为分散剂，让溶剂充分润湿粉体；以400转/min的球磨速度，球磨处理30min，使粉体更好的分散；得到粘度为3Pa.S-5.5Pa.S的初生浆料；
步骤四：第二次超声分散处理
对初生浆料进行第二次超声分散处理，处理时间为10min；
步骤五：第二次球磨处理
采用聚乙烯醇缩丁醛作为粘结剂；采用邻苯二甲酸二丁酯和聚乙二醇的复合物作为复合增塑剂，其中聚乙二醇按重量百分比占35％；以500转/min的球磨速度，球磨处理45min；得到粘度为5Pa.S-8Pa.S的中间浆料；
步骤六：过滤、除泡处理
采用200目的尼龙筛网对中间浆料进行过滤；采用正丁醇：乙二醇＝1:1(重量百分比)的混合物作为除泡剂，真空中搅拌30min，去除浆料在球磨过程中因有机物挥发而产生的气泡；得到粘度为8Pa.S-10Pa.S的成品浆料；
步骤七：流延成型、干燥处理
采用流延机以0.2m/min-0.5m/min的速度对成品浆料进行流延成型，并干燥处理，干燥温度为30℃-50℃；
步骤八：裁剪、叠层、压制
采用裁膜机对干燥后的陶瓷带进行裁剪，采用叠层机对裁剪后的陶瓷带进行叠层，并采用热水均压机进行压制，得到复合前驱体陶瓷带。
与现有技术相比，根据本发明实施例的耐高温电线具有极佳的综合性价比，其制造工艺简单，成本低廉。
综上，根据本发明实施例所制备的耐高温电线，综合运用多种材料和创新性工艺，通过制备高性能柔性复合前驱体陶瓷带，并将其绕包在导体上；由于采用陶瓷带进行绕包，本发明所制备的电线具有极好的柔性；所采用的陶瓷带不依附于其它载体，在高温时不会发生脱落，并能迅速形成完整的陶瓷层。
具体实施方式
为使本发明技术方案和优点更加清楚，通过以下几个具体实施例对本发明作进一步详细描述。显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动的前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1：
复合前驱体陶瓷带的制造过程如下：
步骤一：粉体配料
按重量百分比：CuO 1％、B2O3 0.3％，LiF 2％，La2O3 0.5％，SrTiO3 5％，其余为Al2O3，进行粉体配料，充分搅拌，得到混合粉体；
步骤二：第一次超声分散处理
对混合粉体进行第一次超声分散处理，处理时间为20min；
步骤三：第一次球磨处理
采用95％纯度的工业酒精溶剂和丁酮按重量比3:1形成的二元共沸物作为溶剂，采用蓖麻油作为分散剂，让溶剂充分润湿粉体；以400转/min的球磨速度，球磨处理30min，使粉体更好的分散；得到粘度为3Pa.S的初生浆料；
步骤四：第二次超声分散处理
对初生浆料进行第二次超声分散处理，处理时间为10min；
步骤五：第二次球磨处理
采用聚乙烯醇缩丁醛作为粘结剂；采用邻苯二甲酸二丁酯和聚乙二醇的复合物作为复合增塑剂，其中聚乙二醇按重量百分比占35％；以500转/min的球磨速度，球磨处理45min；得到粘度为5Pa.S的中间浆料；
步骤六：过滤、除泡处理
采用200目的尼龙筛网对中间浆料进行过滤；采用正丁醇：乙二醇＝1:1(重量百分比)的混合物作为除泡剂，真空中搅拌30min，去除浆料在球磨过程中因有机物挥发而产生的气泡；得到粘度为8Pa.S的成品浆料；
步骤七：流延成型、干燥处理
采用流延机以0.2m/min的速度对成品浆料进行流延成型，并干燥处理，干燥温度为30℃；
步骤八：裁剪、叠层、压制
采用裁膜机对干燥后的陶瓷带进行裁剪，采用叠层机对裁剪后的陶瓷带进行叠层，并采用热水均压机进行压制，得到复合前驱体陶瓷带。
根据本发明的示例性实施例，所述陶瓷带厚度为100μm；所述陶瓷带吸水率为0，常温下介电强度≥25KV/mm，体积电阻率≥3×1015Ω·cm，抗拉强度为9Mpa，延伸率为6.05％；所述陶瓷带烧蚀后形成的陶瓷的介电强度≥50KV/mm，体积电阻率≥3×1018Ω·cm。
耐高温电线的制造过程如下：
采用退火圆铜导体，在导体外绕包三层上述制造的陶瓷带，绕包重叠率为50％，绕包后，在陶瓷带外层挤包聚酰胺酰亚胺外绝缘层。
实施例2：
复合前驱体陶瓷带的制造过程如下：
步骤一：粉体配料
按重量百分比：CuO 2％、B2O3 5％，LiF 5％，La2O3 0.8％，SrTiO3 8％，其余为Al2O3，进行粉体配料，充分搅拌，得到混合粉体；
步骤二：第一次超声分散处理
对混合粉体进行第一次超声分散处理，处理时间为20min；
步骤三：第一次球磨处理
采用95％纯度的工业酒精溶剂和丁酮按重量比3:1形成的二元共沸物作为溶剂，采用蓖麻油作为分散剂，让溶剂充分润湿粉体；以400转/min的球磨速度，球磨处理30min，使粉体更好的分散；得到粘度为5Pa.S的初生浆料；
步骤四：第二次超声分散处理
对初生浆料进行第二次超声分散处理，处理时间为10min；
步骤五：第二次球磨处理
采用聚乙烯醇缩丁醛作为粘结剂；采用邻苯二甲酸二丁酯和聚乙二醇的复合物作为复合增塑剂，其中聚乙二醇按重量百分比占35％；以500转/min的球磨速度，球磨处理45min；得到粘度为6Pa.S的中间浆料；
步骤六：过滤、除泡处理
采用200目的尼龙筛网对中间浆料进行过滤；采用正丁醇：乙二醇＝1:1(重量百分比)的混合物作为除泡剂，真空中搅拌30min，去除浆料在球磨过程中因有机物挥发而产生的气泡；得到粘度为8.5Pa.S的成品浆料；
步骤七：流延成型、干燥处理
采用流延机以0.3m/min的速度对成品浆料进行流延成型，并干燥处理，干燥温度为40℃；
步骤八：裁剪、叠层、压制
采用裁膜机对干燥后的陶瓷带进行裁剪，采用叠层机对裁剪后的陶瓷带进行叠层，并采用热水均压机进行压制，得到复合前驱体陶瓷带。
根据本发明的示例性实施例，所述陶瓷带厚度为500μm；所述陶瓷带吸水率为0，常温下介电强度≥25KV/mm，体积电阻率≥3×1015Ω·cm，抗拉强度为10Mpa，延伸率为10.8％；所述陶瓷带烧蚀后形成的陶瓷的介电强度≥50KV/mm，体积电阻率≥3×1018Ω·cm。
耐高温电线的制造过程如下：
采用退火圆铜导体，在导体外绕包两层上述制造的陶瓷带，绕包重叠率为50％，绕包后，在陶瓷带外层挤包聚酰胺酰亚胺外绝缘层。
实施例3：
复合前驱体陶瓷带的制造过程如下：
步骤一：粉体配料
按重量百分比：CuO 5％、B2O3 8.85％，LiF 6.5％，La2O3 0.8％，SrTiO3 8％，其余为Al2O3，进行粉体配料，充分搅拌，得到混合粉体；
步骤二：第一次超声分散处理
对混合粉体进行第一次超声分散处理，处理时间为20min；
步骤三：第一次球磨处理
采用95％纯度的工业酒精溶剂和丁酮按重量比3:1形成的二元共沸物作为溶剂，采用蓖麻油作为分散剂，让溶剂充分润湿粉体；以400转/min的球磨速度，球磨处理30min，使粉体更好的分散；得到粘度为5.5Pa.S的初生浆料；
步骤四：第二次超声分散处理
对初生浆料进行第二次超声分散处理，处理时间为10min；
步骤五：第二次球磨处理
采用聚乙烯醇缩丁醛作为粘结剂；采用邻苯二甲酸二丁酯和聚乙二醇的复合物作为复合增塑剂，其中聚乙二醇按重量百分比占35％；以500转/min的球磨速度，球磨处理45min；得到粘度为8Pa.S的中间浆料；
步骤六：过滤、除泡处理
采用200目的尼龙筛网对中间浆料进行过滤；采用正丁醇：乙二醇＝1:1(重量百分比)的混合物作为除泡剂，真空中搅拌30min，去除浆料在球磨过程中因有机物挥发而产生的气泡；得到粘度为10Pa.S的成品浆料；
步骤七：流延成型、干燥处理
采用流延机以0.5m/min的速度对成品浆料进行流延成型，并干燥处理，干燥温度为50℃；
步骤八：裁剪、叠层、压制
采用裁膜机对干燥后的陶瓷带进行裁剪，采用叠层机对裁剪后的陶瓷带进行叠层，并采用热水均压机进行压制，得到复合前驱体陶瓷带。
根据本发明的示例性实施例，所述陶瓷带厚度为1mm；所述陶瓷带吸水率为0，常温下介电强度≥25KV/mm，体积电阻率≥3×1015Ω·cm，抗拉强度为15Mpa，延伸率为12.9％；所述陶瓷带烧蚀后形成的陶瓷的介电强度≥50KV/mm，体积电阻率≥3×1018Ω·cm。
耐高温电线的制造过程如下：
采用退火圆铜导体，在导体外绕包两层上述制造的陶瓷带，绕包重叠率为50％，绕包后，在陶瓷带外层挤包聚酰胺酰亚胺外绝缘层。
以上所述的具体实施方式，对本发明的目的、技术方案和有益效果进行了进一步详细说明，所应理解的是，以上所述仅为本发明的具体实施方式而已，并不用于限定本发明的保护范围，凡在本发明的精神和原则之内，所做的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (8)

1.一种耐高温电线，其特征在于，所述电线由金属导体、前驱体陶瓷层、外绝缘层组成；所述金属导体为退火圆铜线或铜包铝线；所述前驱体陶瓷层由绕包在金属导体外的复合前驱体陶瓷带构成，所述陶瓷带由按重量百分比的以下成分制成：CuO 1％-5％、B2O3 0.3％-8.85％，LiF 0.15％-6.9％，La2O3 0.1％-1.2％，SrTiO3 2％-18％，其余为Al2O3；所述外绝缘层为聚酰胺酰亚胺薄膜层。
2.根据权利要求1所述的耐高温电线，其特征在于，所述陶瓷带的厚度为100μm-1mm；所述陶瓷带的吸水率为0，常温下所述陶瓷带的介电强度大于或者等于25KV/mm，所述陶瓷带的体积电阻率大于或者等于3×1015Ω·cm，所述陶瓷带的抗拉强度为8Mpa-15Mpa，所述陶瓷带的延伸率为6.05％-12.9％；所述陶瓷带烧蚀后形成的陶瓷的介电强度大于或者等于50KV/mm，其体积电阻率大于或者等于3×1018Ω·cm。
3.一种复合前驱体陶瓷带的制造方法，其特征在于，所述方法包括：
按重量百分比将以下粉体进行配料：CuO 1％-5％、B2O3 0.3％-8.85％，LiF0.15％-6.9％，La2O3 0.1％-1.2％，SrTiO3 2％-18％，其余为Al2O3，经搅拌后得到混合粉体；
对混合粉体进行第一次超声分散处理；
添加溶剂和分散剂，对陶瓷粉体进行第一次球磨处理，得到初生浆料；
对初生浆料进行第二次超声分散处理；
添加粘接剂和复合增塑剂，对陶瓷粉体进行第二次球磨处理，得到中间浆料；
过滤中间浆料，对过筛后的浆料加入除泡剂进行真空搅拌除泡处理，得到成品浆料；
对成品浆料进行流延成型、干燥处理、裁剪、叠层、压制，得到复合前驱体陶瓷带。
4.根据权利要求3所述的方法，其特征在于，所述第一次超声分散处理的时间为20min，第二次超声分散处理的时间为10min。
5.根据权利要求3所述的方法，其特征在于，所述第一次球磨处理时，溶剂为由酒精与丁酮按照重量比为3:1的比例混合得到的二元共沸物，其中酒精纯度为95％；分散剂为蓖麻油；球磨速度为400转/min，球磨时间为30min；初生浆料的粘度为3Pa.S-5.5Pa.S。
6.根据权利要求3所述的方法，其特征在于，所述第二次球磨处理时，粘结剂为聚乙烯醇缩丁醛；复合增塑剂为邻苯二甲酸二丁酯和聚乙二醇的复合物，其中聚乙二醇的重量百分比为35％；球磨速度为500转/min、球磨时间为45min；中间浆料的粘度为5Pa.S-8Pa.S。
7.根据权利要求3所述的方法，其特征在于，采用200目的尼龙筛网对中间浆料进行过滤；真空搅拌除泡处理时，除泡剂为正丁醇与乙二醇按照重量比为1:1的的混合物，真空搅拌时间为30min；成品浆料的粘度为8Pa.S-10Pa.S。
8.根据权利要求3所述的方法，其特征在于，流延成型的速度为0.2m/min-0.5m/min，干燥处理时的干燥温度为30℃-50℃。
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