CN109679266A - 低烟耐高温光伏电缆的制备工艺 - Google Patents

低烟耐高温光伏电缆的制备工艺 Download PDF

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CN109679266A
CN109679266A CN201811633244.8A CN201811633244A CN109679266A CN 109679266 A CN109679266 A CN 109679266A CN 201811633244 A CN201811633244 A CN 201811633244A CN 109679266 A CN109679266 A CN 109679266A
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卜晓华
崔久德
魏三土
安夏天
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Wuxi Xinhongye Wire & Cable Co Ltd
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Abstract

本发明公开一种低烟耐高温光伏电缆的制备工艺，包括以下步骤：将SEBS、苯乙烯类热塑性弹性体、聚苯乙烯、六亚甲基二异氰酸酯、巯基乙酸乙酯加入高速混合机中，在95‑105℃下以500‑800rpm的速度搅拌混合，然后将乙烯‑醋酸乙烯共聚物20~35份、投入螺杆双挤出机中，再加入硬脂酸镁，挤出造粒；将三聚氰胺磷酸铵、水菱镁矿、三聚氰胺焦磷酸盐、聚苯醚、羟基硅油与上述制得的颗粒加入到混炼机上混炼，得到混炼胶。本发明耐折弯无卤光伏电缆扭曲性能能够达到U型弯曲20万次以上，选择180℃扭曲弯曲10万次以上，且有较高耐高温性能优异，达到耐温等级125℃，可以通过158℃×7天的老化，机械性能保留率在80%以上。

Description

低烟耐高温光伏电缆的制备工艺
技术领域
本发明涉及一种光伏电缆，尤其涉及一种低烟耐高温光伏电缆的制备工艺。
背景技术
光伏技术将成为未来的绿色能源技术之一，人们通常不会将连接光伏组件和逆变器的布线系统视为关键部件，但是，不采用光伏应用的专用电缆，将会影响到整个系统的使用寿命。
光伏系统常常会在恶劣环境条件下工作，如高温和紫外线辐射等环境，晴天时，光伏系统的现场温度高达100℃。目前，我们可采用的各种材料有PVC、橡胶、TPE 和高质量交叉链接材料，但是，橡胶电缆的额定温度为90℃，PVC 电缆的额定温度为70℃，这些电缆用于光伏系统将严重影响系统的使用寿命。而常规光伏电缆使用的XLPE材料，耐温等级虽然可以达到100℃，但是材料硬度达到Shore A 93，线材硬度较大，影响柔软性。
在安装和维护期间，电缆多在屋顶等结构的锐边上布线，同时电缆须承受压力、弯折、张力、交叉拉伸载荷及强力冲击。如果电缆的外护套强度不够，则电缆的绝缘层将会受到严重损坏，从而影响整个电缆的使用寿命，严重时导致短路、火灾和人员伤害危险等问题的出现。
发明内容
本发明提供一种低烟耐高温光伏电缆的制备工艺，此制备工艺获得低烟耐高温光伏电缆扭曲性能能够达到U型弯曲20万次以上，选择180℃扭曲弯曲10万次以上，且有较高耐高温性能优异，达到耐温等级125℃，可以通过158℃×7天的老化，机械性能保留率在80%以上。
为达到上述目的，本发明采用的技术方案是：一种低烟耐高温光伏电缆的制备工艺，所述低烟耐高温光伏电缆包括铜导体、包覆于铜导体外表面的内绝缘层和外护套层，所述铜导体由若干根铜丝绞合而成，所述外护套层包覆于内绝缘层外表面；
所述外护套层通过以下步骤获得：
步骤一、将SEBS25~40份、苯乙烯类热塑性弹性体10~20份、聚苯乙烯4~8份、六亚甲基二异氰酸酯2~5份、巯基乙酸乙酯1~2份加入高速混合机中，在95-105℃下以500-800rpm 的速度搅拌混合，然后将乙烯-醋酸乙烯共聚物20~35份、投入螺杆双挤出机中，再加入硬脂酸镁0.2~2份、挤出机熔融段温度控制在140-180℃，在400-600r/min 的转速下熔融共混10-20min，然后挤出造粒，即得颗粒；
步骤二、将三聚氰胺磷酸铵15~30份、水菱镁矿5~10份、三聚氰胺焦磷酸盐2~4份、聚苯醚 1~5份、羟基硅油0.5~1份与上述制得的颗粒加入到混炼机上混炼10~30min，温度为100~120℃，得到混炼胶；
步骤三、将上述制得的混炼胶与油酸酰胺0.2~0.9份、抗氧剂0.4~1.5份、聚偏二氟乙烯1~3份、4-氧代异佛尔酮0.4~0.8份投入密炼机中，密炼机螺杆转速为50-300r/min，温度控制在140~190℃；
步骤四、将密炼后得到的混和料剪切后输送入螺杆挤出机挤出加工，挤出时的机身温度为140±10℃，机头温度为110±10℃，挤出后进行硫化，在160-180℃下热压8-10min，常温冷压4-6min，硫化压力6~10MPa，出线速度为12~15m/min，从而获得电缆料。
上述技术方案中的有关内容解释如下：
1、上述方案中，所述抗氧剂为抗氧剂1010、抗氧剂1098、抗氧剂168、抗氧剂245、抗氧剂1076或硫代二丙酸二硬醇酯中一种或几种的混合物。
2、上述方案中，所述乙烯-醋酸乙烯共聚物中醋酸乙烯含量为16~40%。
3、上述方案中，所述SEBS是以聚苯乙烯为末端段、以乙烯-丁稀共聚物为中间弹性嵌段的线性三嵌共聚物。
4、上述方案中，所述铜丝为5类软铜丝或6类软铜丝。
5、上述方案中，所述凸起部的形状为半圆形。
由于上述技术方案运用，本发明与现有技术相比具有下列优点：
1. 本发明低烟耐高温光伏电缆的制备工艺，其外护套层基于SEBS25~40份、苯乙烯类热塑性弹性体10~20份、聚苯乙烯4~8份中添加六亚甲基二异氰酸酯2~5份，提高电缆料的韧性，改善了电缆曲绕性能，电缆的扭曲性能能够达到U型弯曲20万次以上，选择180℃扭曲弯曲10万次以上；再次，其在配方中添加三聚氰胺磷酸铵15~30份、水菱镁矿5~10份、三聚氰胺焦磷酸盐2~4份、聚苯醚1~5份，提高阻燃效率同时，降低燃烧的发烟量的烟密度小于52Dm，燃烧透光率大于95%。
2. 本发明低烟耐高温光伏电缆的制备工艺，其外护套层配方中进一步添加聚偏二氟乙烯1~3份、4-氧代异佛尔酮0.4~0.8份，使得电缆料有较高耐高温性能优异，达到耐温等级125℃，可以通过158℃×8天的老化，机械性能保留率在80%以上。
附图说明
附图1为本发明低烟耐高温光伏电缆结构示意图。
以上附图中：1、铜导体；101、铜丝；2、内绝缘层；3、外护套层；4、凸起部。
具体实施方式
下面结合实施例对本发明作进一步描述：
实施例1~4：一种低烟耐高温光伏电缆的制备工艺，所述低烟耐高温光伏电缆包括铜导体1、包覆于铜导体1外表面的内绝缘层2和外护套层3，所述铜导体1由若干根铜丝101绞合而成，所述外护套层3包覆于内绝缘层2外表面；
所述外护套层3由以下重量份的组分组成：如表1所示：
表1
实施例1的抗氧剂为抗氧剂1010，实施例2的抗氧剂为抗氧剂245，实施例3的抗氧剂为硫代二丙酸二硬醇酯，实施例4的抗氧剂为抗氧剂168；
上述乙烯-醋酸乙烯共聚物中醋酸乙烯含量为16~40%。
上述SEBS是以聚苯乙烯为末端段、以乙烯-丁稀共聚物为中间弹性嵌段的线性三嵌共聚物。
上述铜丝101为5类软铜丝或6类软铜丝，上述凸起部4的形状为半圆形。
上述外护套层3通过以下步骤获得：
步骤一、将SEBS25~40份、苯乙烯类热塑性弹性体10~20份、聚苯乙烯4~8份、六亚甲基二异氰酸酯2~5份、巯基乙酸乙酯1~2份加入高速混合机中，在95-105℃下以500-800rpm 的速度搅拌混合，然后将乙烯-醋酸乙烯共聚物20~35份、投入螺杆双挤出机中，再加入硬脂酸镁0.2~2份、挤出机熔融段温度控制在140-180℃，在400-600r/min 的转速下熔融共混10-20min，然后挤出造粒，即得颗粒；
步骤二、将三聚氰胺磷酸铵15~30份、水菱镁矿5~10份、三聚氰胺焦磷酸盐2~4份、聚苯醚 1~5份、羟基硅油0.5~1份与上述制得的颗粒加入到混炼机上混炼10~30min，温度为100~120℃，得到混炼胶；
步骤三、将上述制得的混炼胶与油酸酰胺0.2~0.9份、抗氧剂0.4~1.5份、聚偏二氟乙烯1~3份、4-氧代异佛尔酮0.4~0.8份投入密炼机中，密炼机螺杆转速为50-300r/min，温度控制在140~190℃；
步骤四、将密炼后得到的混和料剪切后输送入螺杆挤出机挤出加工，挤出时的机身温度为140±10℃，机头温度为110±10℃，挤出后进行硫化，在160-180℃下热压8-10min，常温冷压4-6min，硫化压力6~10MPa，出线速度为12~15m/min，从而获得电缆料。
实施例1~4：一种上述制备工艺获得的低烟耐高温光伏电缆外护套层3，性能见表2：
表2
采用上述制备工艺获得的低烟耐高温光伏电缆时，其电缆的扭曲性能能够达到U型弯曲20万次以上，选择180℃扭曲弯曲10万次以上；再次，其提高阻燃效率同时，降低燃烧的发烟量的烟密度小于52Dm，燃烧透光率大于95%；再次，其有较高耐高温性能优异，达到耐温等级125℃，可以通过158℃×8天的老化，机械性能保留率在80%以上。
上述实施例只为说明本发明的技术构思及特点，其目的在于让熟悉此项技术的人士能够了解本发明的内容并据以实施，并不能以此限制本发明的保护范围。凡根据本发明精神实质所作的等效变化或修饰，都应涵盖在本发明的保护范围之内。

Claims (6)

1.一种低烟耐高温光伏电缆的制备工艺，其特征在于：所述低烟耐高温光伏电缆包括铜导体（1）、包覆于铜导体（1）外表面的内绝缘层（2）和外护套层（3），所述铜导体（1）由若干根铜丝（101）绞合而成，所述外护套层（3）包覆于内绝缘层（2）外表面；
所述外护套层（3）通过以下步骤获得：
步骤一、将SEBS25~40份、苯乙烯类热塑性弹性体10~20份、聚苯乙烯4~8份、六亚甲基二异氰酸酯2~5份、巯基乙酸乙酯1~2份加入高速混合机中，在95-105℃下以500-800rpm 的速度搅拌混合，然后将乙烯-醋酸乙烯共聚物20~35份、投入螺杆双挤出机中，再加入硬脂酸镁0.2~2份、挤出机熔融段温度控制在140-180℃，在400-600r/min 的转速下熔融共混10-20min，然后挤出造粒，即得颗粒；
步骤二、将三聚氰胺磷酸铵15~30份、水菱镁矿5~10份、三聚氰胺焦磷酸盐2~4份、聚苯醚 1~5份、羟基硅油0.5~1份与上述制得的颗粒加入到混炼机上混炼10~30min，温度为100~120℃，得到混炼胶；
步骤三、将上述制得的混炼胶与油酸酰胺0.2~0.9份、抗氧剂0.4~1.5份、聚偏二氟乙烯1~3份、4-氧代异佛尔酮0.4~0.8份投入密炼机中，密炼机螺杆转速为50-300r/min，温度控制在140~190℃；
步骤四、将密炼后得到的混和料剪切后输送入螺杆挤出机挤出加工，挤出时的机身温度为140±10℃，机头温度为110±10℃，挤出后进行硫化，在160-180℃下热压8-10min，常温冷压4-6min，硫化压力6~10MPa，出线速度为12~15m/min，从而获得电缆料。
2.根据权利要求1所述的低烟耐高温光伏电缆的制备工艺，其特征在于：所述抗氧剂为抗氧剂1010、抗氧剂1098、抗氧剂168、抗氧剂245、抗氧剂1076或硫代二丙酸二硬醇酯中一种或几种的混合物。
3.根据权利要求1所述的低烟耐高温光伏电缆的制备工艺，其特征在于：所述乙烯-醋酸乙烯共聚物中醋酸乙烯含量为16~40%。
4.根据权利要求1所述的低烟耐高温光伏电缆的制备工艺，其特征在于：所述SEBS是以聚苯乙烯为末端段、以乙烯-丁稀共聚物为中间弹性嵌段的线性三嵌共聚物。
5.根据权利要求1所述的低烟耐高温光伏电缆的制备工艺，其特征在于：所述铜丝（101）为5类软铜丝或6类软铜丝。
6.根据权利要求1所述的低烟耐高温光伏电缆的制备工艺，其特征在于：所述凸起部（4）的形状为半圆形。
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