CN108922674A - 一种具有异形填充条的复合电缆及异形填充条制备方法 - Google Patents

一种具有异形填充条的复合电缆及异形填充条制备方法 Download PDF

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CN108922674A
CN108922674A CN201810486176.0A CN201810486176A CN108922674A CN 108922674 A CN108922674 A CN 108922674A CN 201810486176 A CN201810486176 A CN 201810486176A CN 108922674 A CN108922674 A CN 108922674A
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cable
special
shaped packing
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packing
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林耿祥
吉汝忠
邢增茂
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CHENGDU ATLANTIC WIRES AND CABLES Co Ltd
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Abstract

本发明公开了一种具有异形填充条的复合电缆及异形填充条制备方法，复合电缆包括电缆与光缆，电缆包括导体、绝缘层和屏蔽层，导体单丝之间加有阻水粉；光缆包括光纤、松套管和纤膏；所述复合电缆还包括中心加强芯、异形填充条，电缆与光缆间隔设置于异形填充条凹环中；缆芯外依次包覆有云母纤维填充物、防水层、铠装层、外护套。异形填充条由乙烯醋酸乙烯、过氧化二异丙苯、乙烯基三乙氧基硅烷、聚烯烃弹性体按配比混合造粒后，再与线性低密度聚乙稀、增塑剂、抗氧剂1010、发泡剂混合，然后在成缆的同时经挤出机挤出成形。填充条不仅起到填充作用，而且固定电缆和光缆的位置，并将其隔离开来，电缆和光缆互不干扰。

Description

一种具有异形填充条的复合电缆及异形填充条制备方法
技术领域
本发明涉及一种电缆，具体涉及一种具有异形填充条的光电复合电缆及异形填充条制备方法。
背景技术
电线电缆行业是中国仅次于汽车行业的第二大行业，产品品种满足率和国内市场占有率均超过90%。在世界范围内，中国电线电缆总产值已超过美国，成为世界上第一大电线电缆生产国。伴随着中国电线电缆行业高速发展，新增企业数量不断上升，行业整体技术水平得到大幅提高。光电复合缆适用于宽带接入网系统中作传输线，是一种新型的接入方式，它集光纤、输电铜线于一体，可以解决宽带接入、设备用电、信号传输的问题。随着应用领域技术要求的提高，光电复合电缆需具有传输性能稳定，物理性能优良，电缆整体抗拉强度和弯曲强度高，使用寿命长等综合性能。
发明内容
本发明基于上述背景，要解决的问题是：设计一种传输性能稳定，物理性能优良，抗拉强度高，防水性能优异的光电复合电缆，并提出其填充结构的制备方法。
本发明是通过如下技术方案实现的：一种具有异形填充条的复合电缆，包括电缆与光缆，其特征在于：所述电缆包括导体、绝缘层和屏蔽层，所述导体为多股铜芯单丝绞合而成，导体单丝之间加有阻水粉；所述光缆包括光纤、松套管和纤膏，松套管套在光纤外，纤膏填充于光纤与松套管之间；所述复合电缆还包括中心加强芯、异形填充条，所述异形填充条中央有孔洞，所述中心加强芯置于孔洞中，所述异形填充条周围均匀设置有多个凹环，所述电缆与光缆间隔设置于凹环中，异形填充条在成缆过程中与缆芯一起成缆；所述异形填充条外侧从内向外依次包覆有云母纤维填充物、防水层、铠装层、外护套，所述防水层为纵包铝塑复合带层，所述铠装层为涂塑钢带。
进一步地，所述绝缘层为硅烷交联聚乙烯绝缘材料。
进一步地，所述屏蔽层为镀锡铜网状编织层。
进一步地，所述外护套采用改性聚乙烯材料。
进一步地，所述异形填充条是由下述组分及重量份的物料制成：
线性低密度聚乙稀：25～35份；
乙烯醋酸乙烯：65～75份；
聚烯烃弹性体：10～20份
过氧化二异丙苯：10～20份；
氢氧化铝：15～25份；
乙烯基三乙氧基硅烷：35～45份；
增塑剂：16～24份；
抗氧剂1010：2～5份；
发泡剂：1～2份。
一种复合电缆异形填充条制备方法，其特征在于：所述异形填充条制备工艺步骤为：
A：乙烯醋酸乙烯、过氧化二异丙苯、乙烯基三乙氧基硅烷、聚烯烃弹性体按配比加入混合机中混合5～10分钟，然后将混合后的物料造粒，粒度为3～5mm；
B：将步骤A制得的颗粒料与线性低密度聚乙稀、增塑剂、抗氧剂1010、发泡剂一起混合5～10分钟；
C：将步骤B所得的混合料经挤出机在150℃～200℃之间挤出成形。
与现有技术相比，本发明具有以下有益效果：
1、填充结构是一个异形的填充条，填充条上有多个用于放置缆芯的凹环，填充条在成缆的过程中与缆芯一起成缆，各缆芯在按照预先设计的方式排列于填充条的凹环处，填充条不仅起到填充作用，而且固定电缆和光缆的位置，并将其隔离开来，从而保证了电缆和光缆互不干扰，避免缆芯压伤，使得结构稳定，从而提高了电缆的使用寿命。
2、采用本发明制得的填充条，具有良好的阻燃和导热性能，降低了填充结构对电缆传输能力的影响。
3、在填充条中央设有中心加强芯，提高了电缆的抗拉伸能力。
4、在导体单丝之间加有阻水粉，当导体进水时，阻水粉遇水膨胀，堵住缝隙，有效阻止水的进一步渗透。
5、绝缘材料采用硅烷交联聚乙烯，不仅保持了聚乙烯良好的化学稳定性、优异的介电性能，优良的机械性能，还弥补了聚乙烯结构上的缺陷，提高了抗冲击强度、耐热性能、耐环境应力开裂性能。
6、铠装层的设置，增强了电缆的强度，保证其在施工过程中能经受各种碰撞。
7、采用镀锡铜网状编织层作为屏蔽层，保证了电磁干扰环境下系统的传输性能，提高了抵御外来电磁干扰的能力，降低了电缆本身向外辐射电磁波。
附图说明
图1是本发明整体结构示意图。
图2是本发明异形填充条示意图。
其中，1-导体，2-绝缘层，3-屏蔽层，4-光纤，5-松套管，6-纤膏，7-中心加强芯，8-异形填充条，9-云母纤维填充物，10-防水层，11-铠装层，12-外护套，81-孔洞，82-凹环。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅用以解释本发明，并不用于限定本发明。
实施例一：
异形填充条8制备工艺步骤为：
A：取乙烯醋酸乙烯65重量份、过氧化二异丙苯10重量份、乙烯基三乙氧基硅烷35重量份、聚烯烃弹性体10重量份，加入混合机中混合5分钟，然后将混合后的物料造粒，粒度为3mm；
B：取线性低密度聚乙稀25重量份、增塑剂16重量份、2重量份抗氧剂1010、发泡剂1重量份，与步骤A制得的颗粒料一起混合5分钟；
C：在成缆的同时，将步骤B所得的混合料经挤出机挤出成形，挤出机温度控制在190℃～200℃之间。
如图1、2所示，一种具有异形填充条的复合电缆，包括电缆与光缆，其特征在于：所述电缆包括导体1、绝缘层2和屏蔽层3，所述导体1为多股铜芯单丝绞合而成，绞合过程中，在导体1单丝之间加有阻水粉；所述光缆包括光纤4、松套管5和纤膏6，松套管5套在光纤4外，纤膏6填充于光纤4与松套管5之间；所述复合电缆还包括中心加强芯7、异形填充条8，所述异形填充条8中央有孔洞81，所述中心加强芯7置于孔洞81中，所述异形填充条8周围均匀设置有多个凹环82，所述电缆与光缆间隔设置于凹环82中，异形填充条8在成缆过程中与缆芯一起成缆；所述异形填充条8外侧从内向外依次包覆有云母纤维填充物9、防水层10、铠装层11、外护套12，所述防水层10为纵包铝塑复合带层，所述铠装层11为涂塑钢带。
本实施例中，所述绝缘层2为硅烷交联聚乙烯绝缘材料。
本实施例中，所述屏蔽层3为镀锡铜网状编织层。
本实施例中，所述外护套12采用改性聚乙烯材料。
实施例二：
异形填充条8制备工艺步骤为：
A：取乙烯醋酸乙烯75重量份、过氧化二异丙苯20重量份、乙烯基三乙氧基硅烷45重量份、聚烯烃弹性体20重量份，加入混合机中混合10分钟，然后将混合后的物料造粒，粒度为5mm；
B：取线性低密度聚乙稀35重量份、增塑剂24重量份、5重量份抗氧剂1010、发泡剂2重量份，与步骤A制得的颗粒料一起混合10分钟；
C：在成缆的同时，将步骤B所得的混合料经挤出机挤出成形，挤出机温度控制在150℃～160℃之间。
如图1、2所示，一种具有异形填充条的复合电缆，包括电缆与光缆，其特征在于：所述电缆包括导体1、绝缘层2和屏蔽层3，所述导体1为多股铜芯单丝绞合而成，绞合过程中，在导体1单丝之间加有阻水粉；所述光缆包括光纤4、松套管5和纤膏6，松套管5套在光纤4外，纤膏6填充于光纤4与松套管5之间；所述复合电缆还包括中心加强芯7、异形填充条8，所述异形填充条8中央有孔洞81，所述中心加强芯7置于孔洞81中，所述异形填充条8周围均匀设置有多个凹环82，所述电缆与光缆间隔设置于凹环82中，异形填充条8在成缆过程中与缆芯一起成缆；所述异形填充条8外侧从内向外依次包覆有云母纤维填充物9、防水层10、铠装层11、外护套12，所述防水层10为纵包铝塑复合带层，所述铠装层11为涂塑钢带。
本实施例中，所述绝缘层2为硅烷交联聚乙烯绝缘材料。
本实施例中，所述屏蔽层3为镀锡铜网状编织层。
本实施例中，所述外护套12采用改性聚乙烯材料。
实施例三：
异形填充条8制备工艺步骤为：
A：取乙烯醋酸乙烯70重量份、过氧化二异丙苯15重量份、乙烯基三乙氧基硅烷40重量份、聚烯烃弹性体15重量份，加入混合机中混合8分钟，然后将混合后的物料造粒，粒度为4mm；
B：取线性低密度聚乙稀30重量份、增塑剂20重量份、3重量份抗氧剂1010、发泡剂2重量份，与步骤A制得的颗粒料一起混合7分钟；
C：在成缆的同时，将步骤B所得的混合料经挤出机挤出成形，挤出机温度控制在170℃～180℃之间。
如图1、2所示，一种具有异形填充条的复合电缆，包括电缆与光缆，其特征在于：所述电缆包括导体1、绝缘层2和屏蔽层3，所述导体1为多股铜芯单丝绞合而成，绞合过程中，在导体1单丝之间加有阻水粉；所述光缆包括光纤4、松套管5和纤膏6，松套管5套在光纤4外，纤膏6填充于光纤4与松套管5之间；所述复合电缆还包括中心加强芯7、异形填充条8，所述异形填充条8中央有孔洞81，所述中心加强芯7置于孔洞81中，所述异形填充条8周围均匀设置有多个凹环82，所述电缆与光缆间隔设置于凹环82中，异形填充条8在成缆过程中与缆芯一起成缆；所述异形填充条8外侧从内向外依次包覆有云母纤维填充物9、防水层10、铠装层11、外护套12，所述防水层10为纵包铝塑复合带层，所述铠装层11为涂塑钢带。
本实施例中，所述绝缘层2为硅烷交联聚乙烯绝缘材料。
本实施例中，所述屏蔽层3为镀锡铜网状编织层。
本实施例中，所述外护套12采用改性聚乙烯材料。

Claims (6)

1.一种具有异形填充条的复合电缆，包括电缆与光缆，其特征在于：所述电缆包括导体（1）、绝缘层（2）和屏蔽层（3），所述导体（1）为多股铜芯单丝绞合而成，导体（1）单丝之间加有阻水粉；所述光缆包括光纤（4）、松套管（5）和纤膏（6），松套管（5）套在光纤（4）外，纤膏（6）填充于光纤（4）与松套管（5）之间；所述复合电缆还包括中心加强芯（7）、异形填充条（8），所述异形填充条（8）中央有孔洞（81），所述中心加强芯（7）置于孔洞（81）中，所述异形填充条（8）周围均匀设置有多个凹环（82），所述电缆与光缆间隔设置于凹环（82）中，异形填充条（8）在成缆过程中与缆芯一起成缆；所述异形填充条（8）外侧从内向外依次包覆有云母纤维填充物（9）、防水层（10）、铠装层（11）、外护套（12），所述防水层（10）为纵包铝塑复合带层，所述铠装层（11）为涂塑钢带。
2.如权利要求1所述的复合电缆，其特征在于：所述绝缘层（2）为硅烷交联聚乙烯绝缘材料。
3.如权利要求1所述的复合电缆，其特征在于：所述屏蔽层（3）为镀锡铜网状编织层。
4.如权利要求1所述的复合电缆，其特征在于：所述外护套（12）采用改性聚乙烯材料。
5.如权利要求1所述的复合电缆，其特征在于：所述异形填充条（8）是由下述组分及重量份的物料制成：
线性低密度聚乙稀：25～35份；
乙烯醋酸乙烯：65～75份；
聚烯烃弹性体：10～20份
过氧化二异丙苯：10～20份；
氢氧化铝：15～25份；
乙烯基三乙氧基硅烷：35～45份；
增塑剂：16～24份；
抗氧剂1010：2～5份；
发泡剂：1～2份。
6.一种如权利要求5所述的复合电缆的异形填充条制备方法，其特征在于：所述异形填充条（8）制备工艺步骤为：
A：乙烯醋酸乙烯、过氧化二异丙苯、乙烯基三乙氧基硅烷、聚烯烃弹性体按配比加入混合机中混合5～10分钟，然后将混合后的物料造粒，粒度为3～5mm；
B：将步骤A制得的颗粒料与线性低密度聚乙稀、增塑剂、抗氧剂1010、发泡剂一起混合5～10分钟；
C：将步骤B所得的混合料经挤出机在150℃～200℃之间挤出成形。
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