CN109585085A - 抗开裂型铁路信号电缆及其制作方法 - Google Patents
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Abstract
本发明涉及抗开裂型铁路信号电缆及其制作方法,该抗开裂型铁路信号电缆,自内向外依次包括缆芯、缆芯包带层、隔热层、屏蔽层、内垫层、铠装层和外护套,其中隔热层、内垫层和外护套均由凯夫拉纤维内编织层、碳纤维丝外编织层和中间钢丝胶料层通过压延贴合工艺合并形成。本发明抗开裂型铁路信号电缆及其制作方法,通过对电缆结构合理设计,生产制造容易,成本低,具有可靠的屏蔽、阻燃、抗压、抗拉、防潮性能,护套不开裂;且较好地实现了电性能、阻燃性能和机械物理性能的有机统一,能有效保证列车的运行安全。
Description
技术领域
本发明属于电缆制作技术领域,特别涉及一种抗开裂型铁路信号电缆及其制作方法。
背景技术
一直以来,电缆外护套开裂的质量事故时有发生,电缆护套一旦发生开裂,雨水及潮气便会进入电缆内部,使电缆电气性能下降,加速电缆绝缘的老化及金属材料的氧化和腐蚀,轻则造成列车临时停车,重则造成不可挽回的列车安全事故。
以往采用改良材料配方来提高电缆的抗开裂性能,该类方法不能从根本上解决问题,特别是在一些恶劣环境下敷设的电缆,如坚硬物多、电缆长期暴露在外及严寒地区等场合,往往要求电缆具有优越的抗拉、抗压、抗开裂、弯曲性能及机械强度。因此,对现有铁路信号电缆结构进行进一步的技术革新已成为大势所需。
发明内容
本发明的目的是为解决以上问题,本发明提供一种结构简单,设计合理、具有优越的抗拉、抗压、抗开裂、弯曲性能及机械强度的铁路信号电缆。
根据本发明的一个方面,提供一种抗开裂型铁路信号电缆,该铁路信号电缆自内向外依次包括缆芯、缆芯包带层、隔热层、屏蔽层、内垫层、铠装层和外护套,其中隔热层、内垫层和外护套均由凯夫拉纤维内编织层、碳纤维丝外编织层和中间钢丝胶料层通过压延贴合工艺合并形成。
其中,胶料为耐寒高阻燃无卤低烟护套料。
其中,中间钢丝胶料层为沿铁路信号电缆长度方向延伸的数根钢丝间隔分布在胶料中形成。
其中,缆芯包括一个导线组或者相互绞合的数个导线组,每个导线组为由导线绞合形成的对线组和四线组。
其中,导线包括导体和设置在导体外的绝缘层,绝缘层为高密度聚乙烯绝缘料。
其中,缆芯包带层采用无卤玻璃纤维带双层绕包,每层搭盖率≥60%。
其中,铠装层为镀锌钢丝编织而成的编织网。
其中,隔热层与屏蔽层之间填充有阻燃剂氧化镁,形成阻燃剂层;屏蔽层为铝护套屏蔽层;缆芯的线组的绞合节距为缆芯外径的35~55倍。
根据本发明的另一方面,提供该抗开裂型铁路信号电缆的制作方法,其特征在于,包括以下步骤:
在导体外挤塑形成绝缘层形成导线;将导线利用高速星绞机绞合形成导线组;将数个导线组利用高速成缆机绞合形成缆芯;在缆芯外利用无卤玻璃纤维带双层绕包形成缆芯包带层;分别将凯夫拉纤维内编织层、碳纤维丝外编织层和中间钢丝胶料层挂胶,并通过压延工艺结合在一起,一一制成隔热层胶片、内垫层胶片和外护套胶片;将隔热层胶片接缝,使其包覆在缆芯包带层外形成所述隔热层;利用填充工艺和氩弧焊连续焊接工艺在所述隔热层外一次成型完成阻燃剂填充和所述屏蔽层的制作;将内垫层胶片接缝,使其包覆在所述屏蔽层外形成所述内垫层;在内垫层外包覆镀锌钢丝编织网形成所述铠装层;将外护套胶片接缝,使其包覆在所述铠装层外,形成外护套,进而形成所述抗开裂型铁路信号电缆。
其中,制备隔热层胶片、内垫层胶片和外护套胶片的步骤包括:挂胶的胶料的温度为95℃~105℃,压延过程中的辊温为110℃~115℃。
本发明抗开裂型铁路信号电缆及其制作方法,通过对电缆结构合理设计,生产制造容易,成本低,具有可靠的屏蔽、阻燃、抗压、抗拉、防潮性能,护套不开裂;且较好地实现了电性能、阻燃性能和机械物理性能的有机统一,能有效保证列车的运行安全。
附图说明
通过阅读下文优选实施方式的详细描述,各种其他的优点和益处对于本领域普通技术人员将变得清楚明了。附图仅用于示出优选实施方式的目的,而并不认为是对本发明的限制。而且在整个附图中,用相同的参考符号表示相同的部件。在附图中:
图1示出了根据本发明实施方式的抗开裂型铁路信号电缆的截面图。
具体实施方式
下面将参照附图更详细地描述本公开的示例性实施方式。虽然附图中显示了本公开的示例性实施方式,然而应当理解,可以以各种形式实现本公开而不应被这里阐述的实施方式所限制。相反,提供这些实施方式是为了能够更透彻地理解本公开,并且能够将本公开的范围完整的传达给本领域的技术人员。
本发明提供一种抗开裂型铁路信号电缆,该铁路信号电缆自内向外依次包括缆芯1、缆芯包带层5、隔热层6、屏蔽层8、内垫层9、铠装层10和外护套11,其中隔热层5、内垫层9和外护套11均由凯夫拉纤维内编织层和碳纤维丝外编织层和中间钢丝胶料层通过压延贴合工艺合并形成。
钢丝胶料层由数根钢丝经挂胶后,与挂胶后的凯夫拉纤维内编织层和碳纤维丝外编织层压延后形成。优选地,凯夫拉纤维内编织层的厚度为3~10mm,碳纤维丝外编织层的厚度为5~10mm。中间钢丝胶料层的钢丝选用镀锌铜钢丝,钢丝的直径为0.5~2mm。
隔热层6、内垫层9和外护套11均为采用挂胶工艺将三个结构层压延合一的方法制备,能够提升铁路信号电缆的抗压、抗拉能力,使外护套不开裂。胶料优选使用耐寒高阻燃无卤低烟护套料,在提升铁路信号电缆的机械性能的同时能够增强电缆本身的阻燃性能。
缆芯1包括一个导线组2或者相互绞合的数个导线组2,每个导线组2为由导线绞合形成的对线组和四线组。导线包括导体3和设置在导体外的绝缘层4,绝缘层4为高密度聚乙烯绝缘料,不同的导体3外的绝缘层4可通过设置不同颜色进行区分。该高密度聚乙烯绝缘料的耐环境应力开裂试验(老化试验)大于500小时,而低密度聚乙烯仅为48小时。此种绝缘层的透潮性、机械强度、耐磨损性及抗老化性能均明显高于其它类型聚乙烯且其洁净度高、介电性好、介质损耗和介电常数小。绝缘层4的厚度为0.2~1.0mm。在一个具体的实施例中,导体3为铜导体,其直径为0.5~1.5mm。
缆芯包带层5采用无卤玻璃纤维带双层绕包,每层搭盖率≥60%。缆芯包带层的设置不但是电缆具有高阻燃特性,而且具有很好的防鼠作用。
屏蔽层8为铝护套屏蔽层。隔热层与屏蔽铝护套之间设置有氧化镁阻燃剂层。发生火灾时,受到铝护套和填充氧化镁的保护,电缆不会漫延燃烧,外界火苗也不会烧伤缆芯,工作人员能及时对电缆进行维护,降低列车安全系数。
钢丝编织铠装层10是采用镀锌钢丝通过编织工艺编织而成的编织网,镀锌钢丝的直径根据电缆外径的大小可按照GB/T 2952标准要求进行选择。
制作本电缆时,采用拉丝挤塑串列生产线将原铜线拉制成符合技术要求的铜导体3,并在导体外挤塑一层绝缘层4即制成导线。之后根据需求将生产好的2根或4根导线采用高速星绞机绞合制成导线组2,即对线组和四线组。将数个对线组或四线组采用高速成缆机一起绞合制成缆芯1,并在缆芯1外包覆一层缆芯包带层5,再将事先准备好的内层凯夫拉纤维编织层,中间钢丝胶料层,外层碳纤维丝编织层三层合一的护套胶片采用接缝工艺将其包覆在缆芯包带层外制得隔热层6,再采用填充工艺和氩弧焊连续焊接工艺在隔热层6外一次成型完成氧化镁和铝护套屏蔽层8的生产。将事先准备好的内层凯夫拉纤维编织层,中间钢丝胶料层,外层碳纤维丝编织层三层合一的护套胶片采用接缝工艺将其包覆在铝护套屏蔽层外完成内垫层9的制作,之后用镀锌钢丝在内垫层外采用编织工艺包覆一层钢丝编织铠装层10,并在钢丝编织铠装层10外将事先准备好的内层凯夫拉纤维编织层、中间钢丝胶料层、外层碳纤维丝编织层三层合一的护套胶片采用接缝工艺包覆一层外护套11即制成本发明的一种抗开裂型的铁路信号电缆。
在一个优选的实施例中,当隔热层胶片、内垫层胶片和外护套胶片的挂胶时胶料的温度为95~105℃,压延过程中的辊温为110~115℃时,使这三层结构片的抗开裂能力和机械能力综合变现最优。
此外,为确保电缆各项电气性能指标合格,在生产过程中,缆芯1中所有线组必须保持张力一致,导线组的成缆绞合节距的设置范围为缆芯外径的35~55倍。
如图1所示,使用上述方法制成铁路信号电缆A,其中该铁路信号电缆A的缆芯有两个四线组绞合而成。每个四线组由四根导线绞合而成,每根导线由直径为1mm的铜导线外部包覆0.6mm的绝缘层形成。该铁路信号电缆A的缆芯包带层5的搭盖率为70%,屏蔽层为铝护套屏蔽层,隔热层和屏蔽层之间设有绝缘层。隔热层胶片、内垫层胶片和外护套胶片的制作过程中,胶料的温度为100℃,压延过程中的辊温为110℃。
截取长度为50cm的铁路信号电缆A样品进行测试,测试过程和结果如下所示。
加捻旋拧测试:对样品施加4kg旋拧力,加捻时以电缆线样品每1cm处有打结效果时,加捻方向为左旋。
测试结果为:旋拧完毕,外护套正常,没有裂纹和开裂现象,说明该铁路信号电缆A具有良好的抗旋拧冲击能力。
高温压力抗开裂测试:继续将电缆线试样卷曲在试验棒上,卷曲力为6kg,卷曲圈数为7圈,保证试验棒的直径为信号电缆A样品的直径的2倍。将试验棒放入热老化箱中进行测试。
测试结果为:20分钟无开裂现象,显示电缆样品的耐温等级为125℃,说明该铁路信号电缆A具有良好的耐热冲击能力。
以上所述,仅为本发明较佳的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明揭露的技术范围内,可轻易想到的变化或替换,都应涵盖在本发明的保护范围之内。因此,本发明的保护范围应以所述权利要求的保护范围为准。
Claims (10)
1.抗开裂型铁路信号电缆,其特征在于,所述铁路信号电缆自内向外依次包括缆芯(1)、缆芯包带层(5)、隔热层(6)、屏蔽层(8)、内垫层(9)、铠装层(10)和外护套(11),其中所述隔热层(6)、所述内垫层(9)和所述外护套(11)均由凯夫拉纤维内编织层、碳纤维丝外编织层和中间钢丝胶料层通过压延贴合工艺合并形成。
2.如权利要求1所述的抗开裂型铁路信号电缆,其特征在于,
所述缆芯(1)包括一个导线组(2)或者相互绞合的数个导线组(2),每个所述导线组(2)为由导线绞合形成的对线组和四线组。
3.如权利要求2所述的抗开裂型铁路信号电缆,其特征在于,
所述导线包括导体(3)和设置在导体外的绝缘层(4),所述绝缘层(4)为高密度聚乙烯绝缘料。
4.如权利要求1所述的抗开裂型铁路信号电缆,其特征在于,
所述中间钢丝胶料层为沿所述铁路信号电缆长度方向延伸的数根钢丝间隔分布在胶料中形成。
5.如权利要求4所述的抗开裂型铁路信号电缆,其特征在于,
所述胶料为耐寒高阻燃无卤低烟护套料。
6.如权利要求1所述的抗开裂型铁路信号电缆,其特征在于,
所述缆芯包带层(5)采用无卤玻璃纤维带双层绕包,每层搭盖率≥60%。
7.如权利要求1所述的抗开裂型铁路信号电缆,其特征在于,
所述铠装层为镀锌钢丝编织而成的编织网。
8.如权利要求1所述的抗开裂型铁路信号电缆,其特征在于,
所述隔热层(6)与屏蔽层(8)之间填充有阻燃剂氧化镁,形成阻燃剂层(7);所述屏蔽层(8)为铝护套屏蔽层;所述缆芯(1)的导线组的绞合节距为缆芯外径的35~55倍。
9.抗开裂型铁路信号电缆的制作方法,其特征在于,包括以下步骤:
在导体外挤塑形成绝缘层形成导线;
将导线利用星绞机绞合形成导线组;
将数个导线组利用高速成缆机绞合形成所述缆芯;
在所述缆芯外利用无卤玻璃纤维带双层绕包形成所述缆芯包带层;
分别将凯夫拉纤维内编织层、碳纤维丝外编织层和中间钢丝胶料层挂胶,并通过压延工艺结合在一起,一一制成隔热层胶片、内垫层胶片和外护套胶片;
将隔热层胶片接缝,使其包覆在缆芯包带层外形成所述隔热层;
利用填充工艺和氩弧焊连续焊接工艺在所述隔热层外一次成型完成阻燃剂填充和所述屏蔽层的制作;
将内垫层胶片接缝,使其包覆在所述屏蔽层外形成所述内垫层;
在内垫层外包覆镀锌钢丝编织网形成所述铠装层;
将外护套胶片接缝,使其包覆在所述铠装层外,形成外护套,进而形成所述抗开裂型铁路信号电缆。
10.如权利要求9所述抗开裂型铁路信号电缆的制作方法,其特征在于,制备隔热层胶片、内垫层胶片和外护套胶片的步骤包括:
挂胶的胶料的温度为95~105℃,压延过程中的辊温为110~115℃。
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