CN107501796B - 无痕拼接电缆保护套及其制备方法 - Google Patents
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Abstract
无痕拼接电缆保护套及其制备方法,属于电力设施技术领域。解决了如何提供一种强度高、韧性好、阻燃性好、耐腐蚀、寿命长的电缆保护套及其制备方法的问题。本发明的保护套,由交替排列的A段和B段组成,A段和B段的长度比为(2‑4):1,相邻的A段和B段之间熔融连接,A段和B段外表面涂有保护涂料C。该保护套阻燃性好,韧性好,强度高,抗日照,防腐蚀性能优异,能够有效地防止酸碱盐的腐蚀,并且具备较好的耐高温性能,能够长久的对电缆提供有效的防护,避免了安全隐患的发生;经试验检测,该保护套拉伸强度为35MPa以上,断裂伸长率为850%以上,阻燃等级能够达到A级,高温放置或酸碱盐下长时间浸泡,表面均无变化。
Description
技术领域
本发明属于电力设施技术领域,具体涉及一种无痕拼接电缆保护套及其制备方法。
背景技术
近年来,随着生产生活电线电缆的运用日益发展和普及,电线电缆的需求量增加很快,而且随着经济的发展,人们对其性能的要求也越来越高。电缆的保护套设置在电缆最外侧,直接与外界环境接触,与电缆的多种性能息息相关。
电缆应用范围广泛,经常需要在湿热的气候条件下或酸碱盐作用比较严重的区域工作。而一般的电缆保护套材料,湿热的气候条件下或酸碱盐作用比较严重的区域老化、腐蚀、破损现象极易发生,容易引起输电线路故障,给人们正常的生产和生活带来较大的影响,也给电力部门造成较大的损失。为了克服上述缺陷,现有技术已经出现了保护套上使用的防腐涂料,一般采用热喷锌或镀锌等方法刷涂,部分采用防腐涂料涂刷,但是防腐基体处理要求高,涂膜过厚易开裂,漆膜固化时受温度、湿度影响较大,固化时间长,且大都存在耐候性差,粘结力不强的缺点,因此防腐性能普遍不理想。
电缆入地具有不影响交通、对地结构破坏小,周期短等优点。因此,在城市改造过程中,往往需要将架设在空中的各种电缆入地。这就要求电缆具有强度高、刚性韧性好等优点。
在某些特殊区域,电缆又必须裸露在室外,这就要求保护套必须能抵抗日晒、UV辐射、臭氧老化等。
同时电缆燃烧时释放出大量烟雾和有毒的、腐蚀性的气体是火灾中危险因素,在火灾中妨碍了人们的安全撤离和灭火工作,使生命财产遭到严重损失,随着电气火灾事故的频繁发生,电缆的阻燃问题逐渐引起世界各国的重视。
现有技术中,常见的电缆保护套,大都是主要采用聚乙烯、聚丙烯、聚氯乙烯等高分子材料,并加入了一定的添加剂,以改善其相关性能。但是,目前的这些电缆保护套,在强度、刚性、韧性、耐腐蚀性以及阻燃性方面,仍然不理想,或者仅仅在某一方面的性能上面有一定的改进,存在很大的进一步改进的空间。
发明内容
本发明解决的技术问题是如何提供一种强度高、韧性好、阻燃性好、耐腐蚀、寿命长的无痕拼接电缆保护套及其制备方法。
本发明解决上述技术问题取得的技术方案如下。
无痕拼接电缆保护套,由交替排列的A段和B段组成,A段和B段的长度比为(2-4):1,相邻的A段和B段之间熔融连接,A段和B段外表面涂有保护涂料C;
所述A段含有的组分和重量份为:聚氯乙烯100份、硼硅橡胶10-15份、ABS 10-15份、硼砂2-3份、纳米硅胶1-3份、硬脂酸钡5-7份、石蜡3-5份、树胶0.5-1份、白炭黑1-2份、三氧化二锑1-5份、高岭土1-2份;
所述B段含有的组分和重量份为:聚氯乙烯100份、硼硅橡胶10-15份、硬脂酸锌8-15份、复配型阻燃剂10-15份,所述复配型阻燃剂为质量比1:(0.5-1):(0.5-1)的红磷、石墨粉、三氧化二锑的混合物;
所述保护涂料C的粘度为42-50Pa.s,其含有的组分及重量份为:环氧树脂80份、聚四氟乙烯粉10-15份、有机溶剂15-30份、抗UV助剂0.3-0.5份、蛭石1-1.5份、玻璃粉10-12份、石蜡1-5份、纳米银0.1-0.5份、粒度为1000-1250目的空心微珠3-8份。
优选的是,所述A段和B段中,三氧化二锑的粒径均为400目。
优选的是,所述A段和B段还分别含有1-5重量份的颜料。
优选的是,所述A段和B段还分别含有5-10重量份的相容剂。
优选的是,所述有机溶剂为二甲苯。
优选的是,所述保护涂料C还含有分散剂、消泡剂、增稠剂、流平剂中的一种或多种。
上述无痕拼接电缆保护套的制备方法,步骤如下:
步骤一、按A段的组分和重量份称取各物料,混合均匀,得到A段混合料;
步骤二、按B段的组分和重量份称取各物料,混合均匀,得到B段混合料;
步骤三、按保护涂料C的组分和重量份称取各物料,混合均匀,得到保护涂料C;
步骤四、将A组分混合料和B组分混合料分别经螺杆挤出机熔融,并交替的挤入同一挤出模头中,挤出,得到拼接套;
步骤五、将保护涂料C涂敷在拼接套外,固化,得到无痕拼接电缆保护套。
优选的是,挤出温度为165-180℃。
优选的是,所述步骤一和步骤二中,A段和B段的物料分别于搅拌混合机中充分混合均匀,搅拌速度为60-70转/min。
优选的是,步骤三的具体过程是:
将环氧树脂和聚四氟乙烯粉装入搅拌容器中,加入有机溶剂的40%,保持转速为1000r/min搅拌,搅拌0.5-1h使其充分混容,然后将得到的液体料打入分散容器中,加入抗UV助剂、蛭石、玻璃粉、石蜡、纳米银和粒度为1000-1250目的空心微珠,加入剩余的有机溶剂,保持转速为2500r/min,搅拌0.5-1h,得到保护涂料C。
与现有技术相比,本发明有益效果是:
1、本发明的无痕拼接电缆保护套阻燃性好,韧性好,强度高,抗日照,耐高温,防腐蚀性能优异,能够有效地防止酸碱盐的腐蚀,长久的对电缆提供有效的防护,避免了安全隐患的发生;经试验检测,拉伸强度为35MPa以上,断裂伸长率为850%以上,阻燃等级能够达到A级,高温放置或酸碱盐下长时间浸泡,表面均无变化;
2、本发明的无痕拼接电缆保护套的制备方法,简单易操作,且A段和B段采用统一基体树脂,交替挤出,因此A段和B段交接处融合为一体,就有很好的粘结性,结构稳定,外层不易断裂。
附图说明
图1为本发明的无痕拼接电缆保护套未涂覆涂料前,A段和B段拼接后的结构示意图;
图2为本发明的无痕拼接电缆保护套涂覆涂料后的示意图。
具体实施方式
为了进一步了解本发明,下面结合具体实施方式对本发明的优选实施方案进行描述,但是应当理解,这些描述只是为进一步说明本发明的特征和优点而不是对本发明专利要求的限制。
如图1-2所示,无痕拼接电缆保护套,由交替排列的A段和B段组成,A段和B段的长度比为(2-4):1,相邻的A段和B段之间熔融连接,A段和B段外表面涂有保护涂料C,厚度为100-200微米;
其中,A段含有的组分和重量份为:聚氯乙烯100份、硼硅橡胶10-15份、ABS 10-15份、硼砂2-3份、纳米硅胶1-3份、硬脂酸钡5-7份、石蜡3-5份、树胶0.5-1份、白炭黑1-2份、三氧化二锑1-5份和高岭土1-2份;
B段含有的组分和重量份为:聚氯乙烯100份、硼硅橡胶10-15份、硬脂酸锌8-15份和复配型阻燃剂10-15份,所述复配型阻燃剂为质量比1:(0.5-1):(0.5-1)的红磷、石墨粉、三氧化二锑的混合物;
保护涂料C的粘度为42-50Pa.s,其含有的组分及重量份为:环氧树脂80份、聚四氟乙烯粉15份、有机溶剂15-30份、抗UV助剂0.3-0.5份、蛭石1-1.5份、玻璃粉10-12份、石蜡1-5份、纳米银0.1-0.5份和粒度为1000-1250目的空心微珠3-8份。
本发明中,A段和B段还可以含有1-5重量份的颜料,且A段和B段使用的颜料颜色不同,保护涂料C设置为透明的,这样针对于不同的需求可以更有针对性的使用A段和B段,如弯折和受力处更多的使用A段。
本发明中,为了增加相容性,A段和B段还可以含有5-10重量份的相容剂,具体种类没有特殊限制,本领域中常用相容剂即可。为增强保护涂料C的性能,保护涂料C还可以含有分散剂、消泡剂、增稠剂、流平剂中的一种或多种,具体种类为本领域技术人员常规选择。
上述无痕拼接电缆保护套的制备方法,步骤如下:
步骤一、按A段的组分和重量份称取各物料,于搅拌混合机中充分混合均匀,得到A段混合料;
步骤二、按B段的组分和重量份称取各物料,于搅拌混合机中充分混合均匀,得到B段混合料;
步骤三、将环氧树脂和聚四氟乙烯粉装入搅拌容器中,加入有机溶剂总量的的40%,保持转速为1000r/min搅拌,搅拌0.5-1h使其充分混容,然后将得到的液体料打入分散容器中,加入抗UV助剂、蛭石、玻璃粉、石蜡、纳米银和粒度为1000-1250目的空心微珠,加入剩余的有机溶剂,保持转速为2500r/min,搅拌0.5-1h,得到保护涂料C;
步骤四、将A组分混合料和B组分混合料分别经螺杆挤出机熔融,且熔融料交替的挤入同一口径的挤出模头中,挤出,得到拼接套,即先向挤出模头中挤入A组分混合料或B组分混合料,挤出该段保护套,然后停止挤入该混合料,挤入另外一种混合料,这样就挤出另一段保护套,交替进行,由于挤出模头为同一个,保护套的口径相同,又由于基体树脂统一,因此A段和B段交接处融合为一体,就有很好的粘结性;
其中,挤出温度为165-180℃;
步骤五、将保护涂料C涂敷在拼接套外,固化干透,得到无痕拼接电缆保护套。
以下结合实施例进一步说明本发明。
实施例1
无痕拼接电缆保护套,由交替排列的A段和B段组成,A段和B段的长度比为2:1,相邻的A段和B段之间熔融连接,A段和B段外表面涂有保护涂料C,厚度为100微米;
其中,A段的组分和重量份为:聚氯乙烯100份、硼硅橡胶10份、ABS 10份、硼砂2份、纳米硅胶1份、硬脂酸钡5份、石蜡3份、树胶0.5份、白炭黑1份、三氧化二锑1份和高岭土1份;
B段的组分和重量份为:聚氯乙烯100份、硼硅橡胶10份、硬脂酸锌8份和复配型阻燃剂10份,复配型阻燃剂为质量比1:0.5:0.5的红磷、石墨粉、三氧化二锑的混合物;
保护涂料C的粘度为42Pa.s,其组分及重量份为:环氧树脂80份、聚四氟乙烯粉10份、有机溶剂15份、抗UV助剂0.3份、蛭石1份、玻璃粉10份、石蜡1份、纳米银0.1份和粒度为1000目的空心微珠3份。
上述无痕拼接电缆保护套的制备方法:
步骤一、按A段的组分和重量份称取各物料,于搅拌混合机中充分混合均匀,得到A段混合料;
步骤二、按B段的组分和重量份称取各物料,于搅拌混合机中充分混合均匀,得到B段混合料;
步骤三、将环氧树脂和聚四氟乙烯粉装入搅拌容器中,加入有机溶剂总量的40%,保持转速为1000r/min搅拌,搅拌0.5h使其充分混容,然后将得到的液体料打入分散容器中,加入抗UV助剂、蛭石、玻璃粉、石蜡、纳米银和粒度为1250目的空心微珠,加入剩余的有机溶剂,保持转速为2500r/min,搅拌1h,得到保护涂料C;
步骤四、将A组分混合料和B组分混合料分别经螺杆挤出机熔融,且熔融料交替的挤入同一口径的挤出模头中,挤出,挤出温度为165-180℃,得到拼接套;
步骤五、将保护涂料C涂敷在拼接套外,厚度为100微米,固化,得到无痕拼接电缆保护套。
实施例2
无痕拼接电缆保护套,由交替排列的A段和B段组成,A段和B段的长度比为3:1,相邻的A段和B段之间熔融连接,A段和B段外表面涂有保护涂料C,厚度为100微米;
其中,A段的组分和重量份为:聚氯乙烯100份、硼硅橡胶12份、ABS 13份、硼砂2.5份、纳米硅胶2份、硬脂酸钡6份、石蜡4份、树胶0.8份、白炭黑1.5份、三氧化二锑3份和高岭土1.5份;
B段的组分和重量份为:聚氯乙烯100份、硼硅橡胶12份、硬脂酸锌13份和复配型阻燃剂12份,复配型阻燃剂为质量比1:0.5:1的红磷、石墨粉、三氧化二锑的混合物;
保护涂料C的粘度为45Pa.s,其组分及重量份为:环氧树脂80份、聚四氟乙烯粉13份、有机溶剂19份、抗UV助剂0.4份、蛭石1.3份、玻璃粉11份、石蜡3份、纳米银0.5份和粒度为1200目的空心微珠5份。
上述无痕拼接电缆保护套的制备方法:
步骤一、按A段的组分和重量份称取各物料,于搅拌混合机中充分混合均匀,得到A段混合料;
步骤二、按B段的组分和重量份称取各物料,于搅拌混合机中充分混合均匀,得到B段混合料;
步骤三、将环氧树脂和聚四氟乙烯粉装入搅拌容器中,加入有机溶剂总量的40%,保持转速为1000r/min搅拌,搅拌1h使其充分混容,然后将得到的液体料打入分散容器中,加入抗UV助剂、蛭石、玻璃粉、石蜡、纳米银和粒度为1250目的空心微珠,加入剩余的有机溶剂,保持转速为2500r/min,搅拌1h,得到保护涂料C;
步骤四、将A组分混合料和B组分混合料分别经螺杆挤出机熔融,且熔融料交替的挤入同一口径的挤出模头中,挤出,挤出温度为165-180℃,得到拼接套;
步骤五、将保护涂料C涂敷在拼接套外,厚度为100微米,固化,得到无痕拼接电缆保护套。
实施例3
无痕拼接电缆保护套,由交替排列的A段和B段组成,A段和B段的长度比为4:1,相邻的A段和B段之间熔融连接,A段和B段外表面涂有保护涂料C,厚度为100-200微米;
其中,A段的组分和重量份为:聚氯乙烯100份、硼硅橡胶15份、ABS 15份、硼砂3份、纳米硅胶3份、硬脂酸钡7份、石蜡5份、树胶1份、白炭黑2份、三氧化二锑5份和高岭土2份;
B段的组分和重量份为:聚氯乙烯100份、硼硅橡胶15份、硬脂酸锌15份和复配型阻燃剂15份,复配型阻燃剂为质量比1:0.85:1的红磷、石墨粉、三氧化二锑的混合物;
保护涂料C的粘度为50Pa.s,其组分及重量份为:环氧树脂80份、聚四氟乙烯粉15份、有机溶剂30份、抗UV助剂0.5份、蛭石1.5份、玻璃粉12份、石蜡5份、纳米银0.5份和粒度为1250目的空心微珠8份。
上述无痕拼接电缆保护套的制备方法:
步骤一、按A段的组分和重量份称取各物料,于搅拌混合机中充分混合均匀,得到A段混合料;
步骤二、按B段的组分和重量份称取各物料,于搅拌混合机中充分混合均匀,得到B段混合料;
步骤三、将环氧树脂和聚四氟乙烯粉装入搅拌容器中,加入有机溶剂总量的40%,保持转速为1000r/min搅拌,搅拌0.5h使其充分混容,然后将得到的液体料打入分散容器中,加入抗UV助剂、蛭石、玻璃粉、石蜡、纳米银和粒度为1250目的空心微珠,加入剩余的有机溶剂,保持转速为2500r/min,搅拌1h,得到保护涂料C;
步骤四、将A组分混合料和B组分混合料分别经螺杆挤出机熔融,且熔融料交替的挤入同一口径的挤出模头中,挤出,挤出温度为165-180℃,得到拼接套;
步骤五、将保护涂料C涂敷在拼接套外,厚度为100微米,固化,得到无痕拼接电缆保护套。
对实施例1-3的无痕拼接电缆保护套进行检测,检测结果表1所示。测试标准:按照GB/T1040.1-2006的标准测试本发明实施例1-3所得的保护套的拉伸强度和断裂伸长率,按照GB12666.5的标准测试本发明实施例1-3所得的保护套的阻燃等级。
表1实施例1-3的无痕拼接电缆保护套的性能
从表1可以看出,本发明的保护套阻燃性好,韧性好,强度高,防腐蚀性能优异,能够有效地防止酸碱盐的腐蚀,并且具备较好的耐高温性能,能够对电力材料提供有效的防护,避免了安全隐患的发生。
Claims (10)
1.无痕拼接电缆保护套,其特征在于,由交替排列的A段和B段组成,A段和B段的长度比为(2-4):1,相邻的A段和B段之间熔融连接,A段和B段外表面涂有保护涂料C;
所述A段含有的组分和重量份为:聚氯乙烯100份、硼硅橡胶10-15份、ABS 10-15份、硼砂2-3份、纳米硅胶1-3份、硬脂酸钡5-7份、石蜡3-5份、树胶0.5-1份、白炭黑1-2份、三氧化二锑1-5份、高岭土1-2份;
所述B段含有的组分和重量份为:聚氯乙烯100份、硼硅橡胶10-15份、硬脂酸锌8-15份、复配型阻燃剂10-15份,所述复配型阻燃剂为质量比1:(0.5-1):(0.5-1)的红磷、石墨粉、三氧化二锑的混合物;
所述保护涂料C的粘度为42-50Pa.s,其含有的组分及重量份为:环氧树脂80份、聚四氟乙烯粉10-15份、有机溶剂15-30份、抗UV助剂0.3-0.5份、蛭石1-1.5份、玻璃粉10-12份、石蜡1-5份、纳米银0.1-0.5份、粒度为1000-1250目的空心微珠3-8份。
2.根据权利要求1所述的无痕拼接电缆保护套,其特征在于,所述A段和B段中,三氧化二锑的粒径均为400目。
3.根据权利要求1所述的无痕拼接电缆保护套,其特征在于,所述A段和B段还分别含有1-5重量份的颜料。
4.根据权利要求1所述的无痕拼接电缆保护套,其特征在于,所述A段和B段还分别含有5-10重量份的相容剂。
5.根据权利要求1所述的无痕拼接电缆保护套,其特征在于,所述有机溶剂为二甲苯。
6.根据权利要求1所述的无痕拼接电缆保护套,其特征在于,所述保护涂料C还含有分散剂、消泡剂、增稠剂、流平剂中的一种或多种。
7.权利要求1-6任何一项所述的无痕拼接电缆保护套的制备方法,其特征在于,步骤如下:
步骤一、按A段的组分和重量份称取各物料,混合均匀,得到A段混合料;
步骤二、按B段的组分和重量份称取各物料,混合均匀,得到B段混合料;
步骤三、按保护涂料C的组分和重量份称取各物料,混合均匀,得到保护涂料C;
步骤四、将A组分混合料和B组分混合料分别经螺杆挤出机熔融,并交替的挤入同一挤出模头中,挤出,得到拼接套;
步骤五、将保护涂料C涂敷在拼接套外,固化,得到无痕拼接电缆保护套。
8.根据权利要求7所述的无痕拼接电缆保护套的制备方法,其特征在于,挤出温度为165-180℃。
9.根据权利要求7所述的无痕拼接电缆保护套的制备方法,其特征在于,所述步骤一和步骤二中,A段和B段的物料分别于搅拌混合机中充分混合均匀,搅拌速度为60-70转/min。
10.根据权利要求7所述的无痕拼接电缆保护套的制备方法,其特征在于,步骤三的具体过程是:
将环氧树脂和聚四氟乙烯粉装入搅拌容器中,加入有机溶剂的40%,保持转速为1000r/min搅拌,搅拌0.5-1h使其充分混容,然后将得到的液体料打入分散容器中,加入抗UV助剂、蛭石、玻璃粉、石蜡、纳米银和粒度为1000-1250目的空心微珠,加入剩余的有机溶剂,保持转速为2500r/min,搅拌0.5-1h,得到保护涂料C。
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