CN109653585A - 一种高分子复合材料电杆及其制备方法 - Google Patents

一种高分子复合材料电杆及其制备方法 Download PDF

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CN109653585A
CN109653585A CN201811547064.8A CN201811547064A CN109653585A CN 109653585 A CN109653585 A CN 109653585A CN 201811547064 A CN201811547064 A CN 201811547064A CN 109653585 A CN109653585 A CN 109653585A
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electric pole
composite material
layer
winding
lower section
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CN109653585B (zh
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年俊杰
赵军
冯侃
敬中宁
苏心明
吴华
薛振安
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Thomsen Electric Co Ltd
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Abstract

本发明提供了一种复合材料电杆及其制备方法，所述复合材料电杆整体为圆锥形结构，分为上下两段，上下两段的长度比为1:2，通过将甲基乙烯基硅橡胶、辛基酚聚氧乙烯基醚和甲基氯苯基硅油等组分混合，组成高分子基体，复合材料上下段的增强体浸渍高分子基体后通过缠绕工艺生产电杆，由于高分子基体的粘度适中、表面张力小，因此电杆表面较为平整，且省去了涂覆绝缘层的工艺。另外，电杆下段的内芯层由内到外依次为由聚氨酯发泡内芯、芳纶蜂窝和玻璃纤维环氧树脂预浸料蒙皮，由此制备的电杆能满足相关的安全系数值和挠度要求，具有质量轻、绝缘性好、成本较低等优点，且下段省去了脱模工艺，避免因设置拔模角造成底端尺寸过大。

Description

一种高分子复合材料电杆及其制备方法
技术领域
本发明涉及输配电用设施领域，尤其涉及一种高分子复合材料电杆及其制备方法。
背景技术
输电电杆是电力架空线路中的重要承载结构，钢材、混凝土和木材等是目前电杆的主要结构材料。近年来，由于厄尔尼诺现象等原因，各种覆冰、积雪、泥石流、超强台风等自然灾害频繁出现，已发生各类自然灾害事故几千次，如2008年的南方冰雪冻雨灾引起了输电线路大面积断裂，导致169个县停电，大范围主网架相继倒塔，累计停运线路6767条，变电站停运831座，严重威胁电网的安全运行和人民的生命财产安全。因此，电网抢修工程刻不容缓。
但是，传统的钢材、混凝土和木材等材质的电杆，体积大、重量大、搬运困难且易腐蚀倒塌、寿命较短，电杆本身的质量和性能成了电路电网抢修工程的瓶颈，亟需寻求一种质量小、强度高、运输方便、耐腐蚀性和耐候性好、适应性好且寿命较长的电杆，以弥补传统电杆体型笨重、运输困难、塔材腐蚀、杆身裂缝、跳闸率高等缺陷。纤维增强复合材料电杆(以下简称复合材料电杆)由于轻质高强、绝缘性好、耐腐蚀、耐疲劳、易维护和环境适应性好等特点，已经作为一种低碳、节能、可设计性较好的新型结构材料逐渐在输电线路中受到重视。
如北京玻钢院复合材料有限公司公开了一种《复合材料电杆及其制备方法(申请号CN201610770297.9)》，该方法本公开的复合材料电杆包括至少一个缠绕组，缠绕组由内向外依次包括螺旋缠绕层、补强层和环向缠绕层，螺旋缠绕层使用玻璃纤维或玄武岩纤维从所述电杆的根部螺旋缠绕至梢部且厚度为0.5～1mm、缠绕角为1～3°，补强层使用纤维布或者织物从距离所述电杆的根部0.5～1.8m处开始缠绕至距离所述电杆的根部3～8m处且厚度为0.5～1mm，环向缠绕层使用玻璃纤维或玄武岩纤维从所述电杆的根部环向缠绕至梢部且厚度为0.3～0.6mm，同时公开了制备方法。
再比如国网安徽省电力公司黄山供电公司公开了《一种复合材料电杆(申请号CN201721068695.2)》，该电杆包括电杆本体的下段杆、可拆卸装置在下段杆顶部的上段杆、上段杆的根部设置有一组第一固定孔、下段杆的顶部设置有一组和第一装配孔一一对应适配的第二固定孔、上段杆的下端位于第一固定孔的上方设置有一组第一装配孔、下段杆的上端位于第二固定孔的上方设置有一组第二装配孔等，能够有效解决现有复合材料电杆存在的不易装配、拆卸，以及立杆时的安全问题。
现有技术已涉及到了复合材料电杆的结构、制备方法和简易装配结构等内容，但是随着近几年特高压输电工程、智能电网以及新一轮城乡电网改造等重大工程的实施，电路电网建设、抢修用的复合材料电杆依然存在弹性模量小、结构变形大、节点连接强度低、耐腐蚀老化性能随时间下降明显等问题。
发明内容
为了解决上述现有技术中存在的缺陷，本发明的目的是提供一种可满足承受荷载作用下安全重量轻、绝缘性能良好、结构刚度较高、耐腐蚀老化性能持续良好且节点连接强度较大的复合材料电杆，并兼顾搬运方便、安装方便且成本低廉等需要。
为了实现上述目的，本发明采用如下技术方案：
一种复合材料电杆，整体为圆锥形结构，分为上下两段，上下两段的长度比为1:2，其特点在于：下段为实心圆锥结构，下段的根部为圆形底座，下段的主体杆身从内向外分为三层，包括内芯层、缠绕层和加强层，下段的顶部为连接法兰。该结构有助于实现复合材料电杆下段的质量较轻、重心稳定、易于搬运固定且耐腐蚀老化，降低施工人员的劳动强度，节约自然资源。
上段为空心圆锥结构，上段的根部为与下段的顶部为相配合的法兰结构，上段的主体杆身从内向外分为二层，包括缠绕层、加强层，上段的顶部由绝缘材料密封，上段的底部为连接法兰。上段的顶部由绝缘材料密封，该结构有助于复合材料电杆具有足够的长度、质量更轻、耐腐蚀老化并节约资源和成本。
上段和下段复合材料电杆的缠绕层、加强层所用的高分子基体包括如下以重量份计算的组分：
所述高分子基体在均匀混合后，130℃时的粘度为1.6-1.8Pa·s。
特别地，复合材料电杆下段的内芯层为由聚氨酯发泡材料构成的圆锥形结构内芯，在内芯外侧还包覆有一层厚度为0.8-1.2cm的芳纶蜂窝，芳纶蜂窝外侧覆盖有玻璃纤维环氧树脂预浸料蒙皮。该结构有助于分散电杆下段的横向应力，且相比同等长度下水泥结构的电杆重量下降了50～70％，比同等长度下木质结构的重量下降了20％～40％。
特别地，复合材料电杆下段缠绕层为在130-135℃下浸渍高分子基体的玻璃纤维或玄武岩纤维，下段的缠绕层从根部螺旋缠绕至顶部，缠绕层的厚度为0.6～0.8cm，缠绕层数为1～3层，缠绕角为1～3°，为复合材料电杆下段的结构层。
特别地，复合材料电杆下段的加强层为在130-135℃下浸渍高分子基体的玻璃纤维布或石棉纤维布，下段的加强层从下段根部开始缠绕至顶部，共2～4层，总厚度为0.5～1cm，以保证加强层均匀分布、具有较强的抗剪切力。
特别地，复合材料电杆上段的缠绕层为在130-135℃下浸渍高分子基体的玻璃纤维或玄武岩纤维，所述缠绕层在芯模上从上段的根部螺旋缠绕至顶部，缠绕层的厚度为0.3～0.5cm、缠绕层数为1～2层、缠绕角为1～3°，为复合材料电杆上段的结构层。
特别地，复合材料电杆上段的加强层为在130-135℃下浸渍高分子基体的玻璃纤维布或石棉纤维布，所述加强层从电杆上段根部开始缠绕至顶部，共1～2层，总厚度为0.4～0.8cm，并预留缠绕纤维200mm～300mm，加强层从内向外各层的缠绕起点在垂直方向上以0.5m递增、在水平方向上以顺时针60°平移，上段加强层的预留缠绕纤维在脱模后经人工粘胶闭合，以保证加强层均匀分布、具有较强的抗剪切力，且内部不易受到雨雪等不良因素的腐蚀损坏。
特别地，完成加强层缠绕的电杆上段、下段在170℃烘房中水平放置在转轴上，匀速旋转15-20min后即完成硫化，自然冷却后即得高分子复合电杆。
由于采用了上述技术方案，本发明的有益效果如下：(1)本发明通过在甲基乙烯基硅橡胶基体中添加辛基酚聚氧乙烯基醚、甲基氯苯基硅油等组分，使由甲基乙烯基硅橡胶组成的高分子基体在130℃时的粘度为1.6-1.8Pa·s，高分子基体的表面张力较小，且完成缠绕的电杆在烘房中固化时水平匀速转动，一方面可使高分子基体自然流平，保证复合材料电杆具有良好的外观，另一方面，通过控制纤维浸渍高分子基体比例，从而实现高分子基体在纤维层外均匀涂覆，省略了现有技术在电杆最外层增加绝缘层的步骤；(2)本发明使用聚氨酯发泡材料构成电杆下段的圆锥形内芯，在内芯外侧还包覆有一层厚度为0.8-1.2cm的芳纶蜂窝，芳纶蜂窝外侧覆盖有玻璃纤维环氧树脂预浸料蒙皮，并直接在蒙皮外部缠绕浸渍高分子基体的增强纤维，一方面保证了复合材料电杆的弯曲模量可满足使用需求，另一方面，省略了脱模步骤，避免因设置脱模角造成复合材料电杆下段底部直径较大，浪费原材料；(3)本发明提供的复合材料电杆未使用金属骨架结构，同样满足了使用要求，既降低了生产成本，降低了电杆的总体重量，同时也保证了使用的安全；(4)上段的加强层经人工粘胶闭合后，保证内部不易受到雨雪等不良因素的腐蚀损坏；(5)在满足设计工况条件下明显降低了电杆的结构重量，有效改善了传统电杆的重量重、绝缘性差的缺陷，电杆的截面抗弯性能指标应用于实际线路上可有效提高其安全程度，方便安装并可降低成本。
具体实施方式
下面，对本发明的实施方式进行说明。
一种复合材料电杆，整体为圆锥形结构，分为上下两段，上下两段的长度比为1:2，下段为实心圆锥结构，下段的根部为圆形底座，下段的主体杆身从内向外分为五层，包括内芯层、骨架层、缠绕层、加强层和绝缘层，下段的顶部为法兰结构。
上段为空心圆锥结构，上段的根部为与下段的顶部为相配合的法兰结构，上段的主体杆身从内向外分为二层，包括缠绕层、加强层，上段的顶部由绝缘材料密封，保证复合材料电杆内部不受雨雪侵袭，上段的底部为连接法兰。
上段和下段复合材料电杆的缠绕层、加强层所用的高分子基体包括如下以重量份计算的组分：
所述高分子基体在均匀混合后，130℃时的粘度为1.78Pa·s。
复合材料电杆下段的内芯层为由聚氨酯发泡材料构成的圆锥形结构内芯，在内芯外侧还包覆有一层厚度为0.8cm的芳纶蜂窝，芳纶蜂窝外侧覆盖有玻璃纤维环氧树脂预浸料蒙皮。该结构有助于分散电杆下段的横向应力，且相比同等长度下水泥结构的电杆重量下降了50～70％，比同等长度下木质结构的重量下降了20％～40％。
复合材料电杆下段缠绕层为在130℃下浸渍高分子基体的玻璃纤维或玄武岩纤维，下段的缠绕层从内心层根部螺旋缠绕至顶部，缠绕层的厚度为0.8cm，缠绕层数为3层，缠绕角为3°，为复合材料电杆下段的结构层。
复合材料电杆下段的加强层为在130℃下浸渍高分子基体的玻璃纤维布或石棉纤维布，下段的加强层从下段根部开始缠绕至顶部，共3层，总厚度为0.8cm，以保证加强层均匀分布、具有较强的抗剪切力。
复合材料电杆上段的缠绕层为在135℃下浸渍高分子基体的玻璃纤维或玄武岩纤维，所述缠绕层在芯模上从上段的根部螺旋缠绕至顶部，缠绕层的厚度为0.35cm、缠绕层数为2层、缠绕角为2°，为复合材料电杆上段的结构层。
复合材料电杆上段的加强层为在135℃下浸渍高分子基体的玻璃纤维布或石棉纤维布，所述加强层从电杆上段根部开始缠绕至顶部，共2层，总厚度为0.6cm，并预留缠绕纤维280mm，加强层从内向外各层的缠绕起点在垂直方向上以0.5m递增、在水平方向上以顺时针60°平移，上段加强层的预留缠绕纤维在脱模后经人工粘胶闭合。
完成加强层缠绕的电杆上段、下段在170℃烘房中水平放置在转轴上，匀速旋转20min后即完成硫化，自然冷却后即得高分子复合电杆。
复合材料电杆的下段基本性能指标为：在室温25℃、相对湿度40％条件下，电杆的拉伸模量可达43.8GPa，弯曲模量为13.2GPa，剪切模量6.5GPa，耐老化绝缘性能较好。
复合材料电杆的下段基本性能指标为：在室温25℃、相对湿度40％条件下，电杆的拉伸模量可达41.5GPa，弯曲模量为9.6GPa，剪切模量5.9GPa，耐老化绝缘性能较好。符合《架空线路杆塔结构荷载试验》标准要求，完全满足使用需要。
以上实施例为本发明的较佳实施方式，但是，本发明的实施方式并不局限于此，但凡对本发明的各种等价形式的修改替换，均应在本发明的保护范围之内。

Claims (8)

1.一种复合材料电杆，整体为圆锥形结构，分为上下两段，上下两段的长度比为1:2，其特征在于：
(1)下段为实心圆锥结构，下段的根部为圆形，下段的主体杆身从内向外分为三层，包括内芯层、缠绕层和加强层，下段的顶部为连接法兰；
(2)上段为空心圆锥结构，上段的根部为与下段的顶部为相配合的法兰结构，上段的主体杆身从内向外分为二层，包括缠绕层、加强层，上段的顶部由绝缘材料密封，上段的底部为连接法兰；
上段和下段复合材料电杆的缠绕层、加强层所用的高分子基体包括如下以重量份计算的组分：
所述高分子基体在均匀混合后，130℃时的粘度为1.6-1.8Pa·s。
2.如权利要求1所述的复合材料电杆，其特征在于，所述复合材料电杆下段的内芯层为由聚氨酯发泡材料构成的圆锥形结构内芯，在内芯外侧还包覆有一层厚度为0.8-1.2cm的芳纶蜂窝，芳纶蜂窝外侧覆盖有玻璃纤维环氧树脂预浸料蒙皮。
3.如权利要求1所述的复合材料电杆，其特征在于，所述复合材料电杆下段缠绕层为在130-135℃下浸渍高分子基体的玻璃纤维或玄武岩纤维，下段的缠绕层从根部螺旋缠绕至顶部，缠绕层的厚度为0.6～0.8cm，缠绕层数为1～3层，缠绕角为1～3°。
4.如权利要求1所述的复合材料电杆，其特征在于，所述复合材料电杆下段的加强层为在130-135℃下浸渍高分子基体的玻璃纤维布或石棉纤维布，下段的加强层从下段根部开始缠绕至顶部，共2～4层，总厚度为0.5～1cm。
5.如权利要求1所述的复合材料电杆，其特征在于，所述复合材料电杆上段的缠绕层为在130-135℃下浸渍高分子基体的玻璃纤维或玄武岩纤维，所述缠绕层在芯模上从上段的根部螺旋缠绕至顶部，缠绕层的厚度为0.3～0.5cm、缠绕层数为1～2层、缠绕角为1～3°。
6.如权利要求1所述的复合材料电杆，其特征在于，所述复合材料电杆上段的加强层为在130-135℃下浸渍高分子基体的玻璃纤维布或石棉纤维布，所述加强层从电杆上段根部开始缠绕至顶部，共1～2层，总厚度为0.4～0.8cm，并预留缠绕纤维200mm～300mm，加强层从内向外各层的缠绕起点在垂直方向上以0.5m递增、在水平方向上以顺时针60°平移。
7.如权利要求6所述的复合材料电杆，其特征在于，所述复合材料电杆上段加强层的预留缠绕纤维在脱模后经人工粘胶闭合。
8.如权利要求1所述的复合材料电杆，其特征在于，所述完成加强层缠绕的电杆上段、下段在170℃烘房中水平放置在转轴上，匀速旋转15-20min后即完成硫化。
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