CN110010280A - 一种碳纤维复合导体电缆及其生产工艺 - Google Patents
一种碳纤维复合导体电缆及其生产工艺 Download PDFInfo
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Abstract
本发明公开了一种碳纤维复合导体电缆及其生产工艺，包括有橡胶骨架，所述的橡胶骨架为空心十字型，在橡胶骨架的内部中心处设有线芯一，在线芯一的四周均布有线芯二，在橡胶骨架的四个侧面分别设有锥形封板，在橡胶骨架的外侧依次包覆有交联乙烯四氟乙烯共聚物绝缘层、碳纤维丝与镀锡钢丝混合编织套、纳米硅防水胶填充层、铝合金带联锁铠装层和氯磺化聚乙烯外护套。本发明采用了带有十字型空腔的橡胶骨架，结构简单新颖，线芯都放入骨架内部，起到保护线芯的作用，不仅增加电缆的抗压抗拉性能，还增加电缆的柔韧性，延长使用寿命。
Description
技术领域
本发明涉及电缆技术领域，尤其涉及一种碳纤维复合导体电缆及其生产工艺。
背景技术
现有的电缆，一般采用镀锌钢丝作为线芯，外层绞合圆形的铝合金线。这种电缆主要存在以下几方面的问题 ：一、由于外层绞合的是圆形的铝合金线，导致线与线之间的间隙大，有效截面积小，且外径大，储存和运输过程中占用空间大。二、所用镀锌钢丝的抗拉强度低，重量大，架设时跨距较小，架设电缆所需的杆塔数量多，不但成本大，浪费人力物力，而且占用土地资源多。
发明内容
本发明目的就是为了弥补已有技术的缺陷，提供一种碳纤维复合导体电缆及其生产工艺。
本发明是通过以下技术方案实现的：
一种碳纤维复合导体电缆，包括有橡胶骨架，所述的橡胶骨架为空心十字型，在橡胶骨架的内部中心处设有线芯一，在线芯一的四周均布有线芯二，在橡胶骨架的四个侧面分别设有锥形封板，在橡胶骨架的外侧依次包覆有交联乙烯四氟乙烯共聚物绝缘层、碳纤维丝与镀锡钢丝混合编织套、纳米硅防水胶填充层、铝合金带联锁铠装层和氯磺化聚乙烯外护套，所述的线芯一包括有导体一以及依次包覆在导体一外侧的聚烯烃绝缘层和铜塑复合带绕包层，所述的线芯二包括有导体二以及依次包覆在导体二外侧的聚丙烯绝缘层、凯芙拉纤维编织层和碳素波纹管，所述的导体一和导体二均是由镀锡铜丝与碳纤维丝束绞而成的。
一种碳纤维复合导体电缆的生产工艺，具体包括以下步骤：
（1）将单铜丝利用拉丝机在常温下进行拉伸，再将单铜丝放入退火炉内进行强制退火，退火温度为250-350度，退火时间20-25分钟，制成铜单丝，再铜单丝表面喷涂锡层，再将多根铜单丝与多根碳纤维丝束绞，分别制成导体一和导体二；
（2）在导体一的外侧挤包聚烯烃绝缘层，冷却2小时后，在聚烯烃绝缘层外包覆铜塑复合带，采用无缝焊接进行固定，制成线芯一；
（3）在导体二的外侧挤包聚丙烯绝缘层，冷却2小时后，将凯芙拉纤维编织层包裹在聚丙烯绝缘层外侧，编织密度为90%，再将碳素波纹管套在凯夫拉纤维编织层外侧，得到线芯二；
（4）在橡胶锥形封板的两侧焊接左右橡胶挡板，构成四分之一骨架，将四根线芯二分别放入四个所述的四分之一骨架内侧，将一根线芯一放在四根线芯二中间，将四个四分之一骨架的左右挡板依次焊接连接，构成带有十字型空腔的橡胶骨架，橡胶骨架与线芯一和线芯二共同构成缆芯；
（5）在缆芯的外侧挤包交联乙烯四氟乙烯共聚物绝缘层，冷却2小时后，将碳纤维丝与镀锡钢丝混合编织层包裹在交联乙烯四氟乙烯共聚物绝缘层外侧，编织密度为90%，将碳纤维丝与镀锡钢丝混合编织层熔融成碳纤维丝与镀锡钢丝混合编织套，在碳纤维丝与镀锡钢丝混合编织套外侧涂抹纳米硅防水胶，待防水胶凝固后，再包上铝合金带联锁铠装层，最后挤包氯磺化聚乙烯外护套，冷却4小时后，得成品电缆。
所述的碳纤维丝与镀锡钢丝混合编织层的熔融条件为：熔融温度为100-150度，熔融时间5-15分钟，并用5-10度空气吹扫冷却。
碳素波纹管采用高密度聚乙烯原材料及碳素粒子等添加剂，经真空吸塑成型工艺，生产一种具有波纹形闭合环状管壁结构的管道。该管具有重量轻、弯曲半径小、抗外压强度高、绝缘电阻小、耐腐蚀、不渗漏、防鼠咬、耐候性好、产率高，遇障碍可绕性等一系列优点。
本发明的优点是：本发明采用了带有十字型空腔的橡胶骨架，结构简单新颖，线芯都放入骨架内部，起到保护线芯的作用，不仅增加电缆的抗压抗拉性能，还增加电缆的柔韧性，延长使用寿命；另外导体采用镀锡铜丝加碳纤维丝束绞而成的，增加导体的柔软性能，不易断裂；将铜单丝进行拉丝再退火，通过加热再结晶的方式提高单丝的韧性，更耐用；将碳纤维丝与镀锡钢丝混合编织层熔融成碳纤维丝与镀锡钢丝混合编织套，结构更加稳定，不易开裂，粘接覆盖性能更好，不易脱落。
附图说明
图1为本发明的结构示意图。
具体实施方式
如图1所示，一种碳纤维复合导体电缆，包括有橡胶骨架1，所述的橡胶骨架1为空心十字型，在橡胶骨架1的内部中心处设有线芯一，在线芯一的四周均布有线芯二，在橡胶骨架1的四个侧面分别设有锥形封板2，在橡胶骨架1的外侧依次包覆有交联乙烯四氟乙烯共聚物绝缘层3、碳纤维丝与镀锡钢丝混合编织套4、纳米硅防水胶填充层5、铝合金带联锁铠装层6和氯磺化聚乙烯外护套7，所述的线芯一包括有导体一8以及依次包覆在导体一8外侧的聚烯烃绝缘层9和铜塑复合带绕包层10，所述的线芯二包括有导体二11以及依次包覆在导体二11外侧的聚丙烯绝缘层12、凯芙拉纤维编织层13和碳素波纹管14，所述的导体一8和导体二11均是由镀锡铜丝与碳纤维丝束绞而成的。
一种碳纤维复合导体电缆的生产工艺，具体包括以下步骤：
（1）将单铜丝利用拉丝机在常温下进行拉伸，再将单铜丝放入退火炉内进行强制退火，退火温度为250-350度，退火时间20-25分钟，制成铜单丝，再铜单丝表面喷涂锡层，再将多根铜单丝与多根碳纤维丝束绞，分别制成导体一和导体二；
（2）在导体一的外侧挤包聚烯烃绝缘层，冷却2小时后，在聚烯烃绝缘层外包覆铜塑复合带，采用无缝焊接进行固定，制成线芯一；
（3）在导体二的外侧挤包聚丙烯绝缘层，冷却2小时后，将凯芙拉纤维编织层包裹在聚丙烯绝缘层外侧，编织密度为90%，再将碳素波纹管套在凯夫拉纤维编织层外侧，得到线芯二；
（4）在橡胶锥形封板的两侧焊接左右橡胶挡板，构成四分之一骨架，将四根线芯二分别放入四个所述的四分之一骨架内侧，将一根线芯一放在四根线芯二中间，将四个四分之一骨架的左右挡板依次焊接连接，构成带有十字型空腔的橡胶骨架，橡胶骨架与线芯一和线芯二共同构成缆芯；橡胶骨架的长度和宽度取决于线芯一和线芯二的直径，使四个线芯二与橡胶骨架内壁紧密接触；
（5）在缆芯的外侧挤包交联乙烯四氟乙烯共聚物绝缘层，冷却2小时后，将碳纤维丝与镀锡钢丝混合编织层包裹在交联乙烯四氟乙烯共聚物绝缘层外侧，编织密度为90%，将碳纤维丝与镀锡钢丝混合编织层熔融成碳纤维丝与镀锡钢丝混合编织套，在碳纤维丝与镀锡钢丝混合编织套外侧涂抹纳米硅防水胶，待防水胶凝固后，再包上铝合金带联锁铠装层，最后挤包氯磺化聚乙烯外护套，冷却4小时后，得成品电缆。
所述的碳纤维丝与镀锡钢丝混合编织层的熔融条件为：熔融温度为100-150度，熔融时间5-15分钟，并用5-10度空气吹扫冷却。
Claims (3)
1.一种碳纤维复合导体电缆，其特征在于：包括有橡胶骨架，所述的橡胶骨架为空心十字型，在橡胶骨架的内部中心处设有线芯一，在线芯一的四周均布有线芯二，在橡胶骨架的四个侧面分别设有锥形封板，在橡胶骨架的外侧依次包覆有交联乙烯四氟乙烯共聚物绝缘层、碳纤维丝与镀锡钢丝混合编织套、纳米硅防水胶填充层、铝合金带联锁铠装层和氯磺化聚乙烯外护套，所述的线芯一包括有导体一以及依次包覆在导体一外侧的聚烯烃绝缘层和铜塑复合带绕包层，所述的线芯二包括有导体二以及依次包覆在导体二外侧的聚丙烯绝缘层、凯芙拉纤维编织层和碳素波纹管，所述的导体一和导体二均是由镀锡铜丝与碳纤维丝束绞而成的。
2.一种碳纤维复合导体电缆的生产工艺，其特征在于：具体包括以下步骤：
（1）将单铜丝利用拉丝机在常温下进行拉伸，再将单铜丝放入退火炉内进行强制退火，退火温度为250-350度，退火时间20-25分钟，制成铜单丝，再铜单丝表面喷涂锡层，再将多根铜单丝与多根碳纤维丝束绞，分别制成导体一和导体二；
（2）在导体一的外侧挤包聚烯烃绝缘层，冷却2小时后，在聚烯烃绝缘层外包覆铜塑复合带，采用无缝焊接进行固定，制成线芯一；
（3）在导体二的外侧挤包聚丙烯绝缘层，冷却2小时后，将凯芙拉纤维编织层包裹在聚丙烯绝缘层外侧，编织密度为90%，再将碳素波纹管套在凯夫拉纤维编织层外侧，得到线芯二；
（4）在橡胶锥形封板的两侧焊接左右橡胶挡板，构成四分之一骨架，将四根线芯二分别放入四个所述的四分之一骨架内侧，将一根线芯一放在四根线芯二中间，将四个四分之一骨架的左右挡板依次焊接连接，构成带有十字型空腔的橡胶骨架，橡胶骨架与线芯一和线芯二共同构成缆芯；
（5）在缆芯的外侧挤包交联乙烯四氟乙烯共聚物绝缘层，冷却2小时后，将碳纤维丝与镀锡钢丝混合编织层包裹在交联乙烯四氟乙烯共聚物绝缘层外侧，编织密度为90%，将碳纤维丝与镀锡钢丝混合编织层熔融成碳纤维丝与镀锡钢丝混合编织套，在碳纤维丝与镀锡钢丝混合编织套外侧涂抹纳米硅防水胶，待防水胶凝固后，再包上铝合金带联锁铠装层，最后挤包氯磺化聚乙烯外护套，冷却4小时后，得成品电缆。
3.根据权利要求2所述的一种碳纤维复合导体电缆的生产工艺，其特征在于：所述的碳纤维丝与镀锡钢丝混合编织层的熔融条件为：熔融温度为100-150度，熔融时间5-15分钟，并用5-10度空气吹扫冷却。
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