CN110491603A - 一种防虫害防水电力电缆的生产工艺 - Google Patents

一种防虫害防水电力电缆的生产工艺 Download PDF

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CN110491603A
CN110491603A CN201910848902.3A CN201910848902A CN110491603A CN 110491603 A CN110491603 A CN 110491603A CN 201910848902 A CN201910848902 A CN 201910848902A CN 110491603 A CN110491603 A CN 110491603A
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pest
insect
waterproof
power cable
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张宇
王新国
刘威
于阳
连钧宇
韩淑杰
桂裕聪
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Jiangsu Hengtong Power Cable Co Ltd
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Abstract

本发明公开了一种防虫害防水电力电缆的生产工艺,包括如下步骤:S1、制备导体;S2、制备绝缘层;S3、制备缆芯;S4、制备防水与防虫害共挤层:在S3制备的缆芯外纵包双面铝塑复合带,通过喇叭模将铝塑复合带收紧到紧贴缆芯的大小,再经过加热装置进行加热,通过加热装置使铝塑复合带的塑面相互黏贴,紧密粘合在一起,构成第一步径向防水层;缆芯包覆双面铝塑复合带后,采用双层共挤挤出机进行双层共挤,内层采用聚乙烯材料,挤出标称厚度应为2.0mm,作为第二步径向防水层,外层采用尼龙材料,挤出厚度应不小于0.2mm,作为防虫害层;S5、制备外护层。使用该工艺生产出的电缆具有纵向阻水性能和径向阻水性能,并且实现物理防虫害特性。

Description

一种防虫害防水电力电缆的生产工艺
技术领域
本发明涉及电缆制造领域,具体涉及防虫害防水电力电缆的生产工艺。
背景技术
目前,电力电缆的敷设安装环境越来越复杂,部分电缆沟(井)因设计原因或其他不可抗拒因素,均长期浸泡于水中,有的井(沟)水深达1m左右,因排水困难,电缆巡视人员无法下井进行正常巡视,影响到电缆巡视质量,而电缆受潮或进水对电缆性能影响巨大。
电线电缆若发生受潮或进水现象,将会严重影响其安全性能和使用性能。通电过程中,极易造成电线电缆短路或火花现象,造成电线电缆绝缘击穿、短路,甚至造成电线电缆火灾事故。更为致命的是,电线电缆受潮和进水,也将降低电线电缆的各项物理性能,加快电线电缆绝缘老化速度,降低使用寿命,电缆导体进水后,进水量大时,水分可沿着导体纵向方向蔓延,电缆通电后主绝缘靠近导体线芯侧产生水树枝,并进而导发电树枝,最后导致主绝缘击穿。因此交联电缆内部进水的后果严重性。
另外,国内部分地区要求电缆具有防虫害特性,现防虫害采用化学方法来实现,即在电缆的外护套内增加化学制剂来达到防虫害的特性,但这种方法可能造成电缆护套生产人员及安装敷设施工人员产生过敏现象。引起身体不适。
发明内容
本发明要解决的技术问题是提供一种防虫害防水电力电缆的生产工艺,使用该工艺生产出的电缆具有纵向阻水性能和径向阻水性能,并且实现物理防虫害特性。
为了解决上述技术问题,本发明提供了一种防虫害防水电力电缆的生产工艺,包括如下步骤:
S1、制备导体:金属杆材在外力的作用下,经过拉伸模具得到导线单丝,以一根导线单丝为中心,将多根导线单丝分层、多次、正反向绞合在中心的导线单丝外侧制成导体,在多层导线单丝之间填充阻水材料,在导体外绕包有阻水带;
S2、制备绝缘层:在S1制备的导体外挤包交联聚乙烯绝缘层;
S3、制备缆芯:将多根制备的导体进行绞合,采用非吸湿性填充物填充在导体内部的间隙中,采用非吸湿性包带绕包在多根导体外侧,构成缆芯;
S4、制备防水与防虫害共挤层:在S3制备的缆芯外纵包双面铝塑复合带,通过喇叭模将铝塑复合带收紧到紧贴缆芯的大小,再经过加热装置进行加热,通过加热装置使铝塑复合带的塑面相互黏贴,紧密粘合在一起,构成第一步径向防水层;
缆芯包覆双面铝塑复合带后,采用双层共挤挤出机进行双层共挤,内层采用聚乙烯材料,挤出标称厚度应为2.0mm,作为第二步径向防水层,外层采用尼龙材料,挤出厚度应不小于0.2mm,作为防虫害层;
S5、制备外护层:在S4制备的防水与防虫害共挤层外挤包外护层。
本发明一个较佳实施例中,进一步包括步骤S1中,导线拉丝的过程中,在拉丝模具内添加润滑液,保持拉丝模具内通畅,润滑液的配比浓度为2%~10%。
本发明一个较佳实施例中,进一步包括所述润滑液循环使用,温度控制在10℃~65℃之间,并且需要使用折光仪定期测试润滑液的浓度。
本发明一个较佳实施例中,进一步包括步骤S1中,任意相邻两层的导线单丝绞合方向相反,绞合在最外层的导线单丝的节径比为12~20,绞合在内层的导线单丝的节径比为20~40。
本发明一个较佳实施例中,进一步包括步骤S2中,交联聚乙烯绝缘层的耐温等级在-40℃~90℃之间。
本发明一个较佳实施例中,进一步包括步骤S3中,采用的非吸湿性填充物和非吸湿性包带均在温度为50±5℃的烘箱中预处理24±1小时,接着在干燥器中冷却,然后在温度为20±5℃、湿度为95±4%的环境中放置48小时,使其吸收的水分重量不超过5%。
本发明一个较佳实施例中,进一步包括步骤S3中,所述非吸湿性包带为标称厚度0.2mm的2层非吸湿性无纺布,绕包重叠率≥25%。
本发明一个较佳实施例中,进一步包括步骤S4中,双面铝塑复合带包括铝带和包覆在铝带两侧的塑料膜,所述铝带和塑料膜之间不分层,所述双面铝塑复合带的标称厚度为0.3mm。
本发明一个较佳实施例中,进一步包括步骤S5中,所述外护层采用聚乙烯或聚氯乙烯材料。
本发明一个较佳实施例中,进一步包括在步骤S5制备外护套前,制备金属铠装层,所述金属铠装层采用镀锌钢带纵包在所述防水与防虫害共挤层外侧,或采用若干根不锈钢丝绕包在防水与防虫害共挤层外侧。
本发明的有益效果:
其一、本发明在制备导体的过程中,在若干层导线单丝之间填充阻水材料,用于填充导线单丝之间的间隙,防止水分从间隙中渗入,实现了导体内部的纵向防水效果;并且在导体的外部绕包有阻水带,防止水分从外部流入,实现了导体内的径向防水效果。
其二、本发明采用防水与防虫害共挤设计,采用纵包双面铝塑复合带加热,使双面铝塑复合带的塑料膜融化紧密黏贴在缆芯外侧,构成了缆芯中第一步的径向防水层,并且纵包的双面铝塑复合带也具有一定的纵向阻水能力;采用双层共挤挤出机进行双层共挤,内层采用聚乙烯材料,挤出标称厚度应为2.0mm,作为第二步径向防水层,外层采用尼龙材料,挤出厚度应不小于0.2mm,作为防虫害层,实现物理防虫害。更加环保,避免了敷设人员的过敏现象。
其三、采用双层共挤技术,防止阻水层与防虫害层之间出现渗水的情况,进一步保证电缆层与层之间的阻水效果;并且径向防水层和防虫害层通过一道工序完成,节约了人工成本。
附图说明
图1是本发明的防虫害防水电力电缆的生产工艺的步骤图;
图2是本发明的防虫害防水电力电缆的一实施例的结构示意图。
图中标号说明:1、;2、;3、;4、;5、;6、;7、;8、;9、;10、;
具体实施方式
下面结合附图和具体实施例对本发明作进一步说明,以使本领域的技术人员可以更好地理解本发明并能予以实施,但所举实施例不作为对本发明的限定。
参照图1所示,本发明的防虫害防水电力电缆的生产工艺的制造步骤;
S1、制备导体:金属杆材在外力的作用下,经过拉伸模具得到导线单丝,以一根导线单丝为中心,将多根导线单丝分层、多次、正反向绞合在中心的导线单丝外侧制成导体,在多层导线单丝之间填充阻水材料,在导体外绕包有阻水带;
本实施例中,选取金属杆材为含铜率为99.99%的铜杆,在拉丝的过程中,在拉丝模具内添加润滑液,保持拉丝模具内通畅,并且要保证模座和模孔内不得有杂质、铜屑和铝屑堆积,以免影响润滑效果和模子的使用寿命;其中,润滑液的配比浓度为2%~10%,根据使用的拉力机的拉力情况进行调整,拉力约大,使用的润滑液的配比浓度越高。
具体地,所述润滑液循环使用,温度控制在10℃~65℃之间,以确保润滑液(油)的润滑效果,并且需要使用折光仪定期测试润滑液的浓度,当浓度不足时,要及时添加润滑液调节浓度以达到规定。
具体地,若干根导线单丝采用标准的绞合方式进行绞合,即每根导线单丝的外径相同,以导线单丝为中心,在中心导线单丝外绞合的第一层为6根导线单丝,第二层为12根导线单丝,第三层为18根导线单丝,以此类推,根据实际的需求情况设置多层的导线单丝,任意相邻两层的导线单丝绞合方向相反,一方面使绞合更加紧密,另一方面正反绞合的设计,可实现扭矩平衡,保证两方向的扭转刚度基本一致,提升产品抗扭性能,绞合在最外层的导线单丝的节径比为12~20,绞合在内层的导线单丝的节径比为20~40,导体绞合节距允许偏差为:外层为±20mm,其余各层为±40mm。
具体地,金属杆材拉丝过程中会出现拉断的情况,导体不允许整根焊接,导线单丝断头可焊接修补,但同一截面上不允许有两个及以上接头,同一层内的相邻两个接头间的距离应不小于100mm,铜单丝焊接应采用电阻对焊或冷压对焊,电阻对焊的接头应退火,退火长度每侧为200mm左右,铝单丝焊接应采用冷压对焊,焊接点应修理平整,其外径不大于单丝外径的110%,7根及以下成品导体不允许焊接。
在多层导线单丝之间填充的阻水材料可以选择阻水粉、阻水纱、阻水带,如果选用阻水带,应该在层与层之间纵包阻水带,并且要保证相邻两层导线单丝之间的紧压系数不小于0.9,这样这样才能保证阻水带会被压迫,使阻水带完全填充在导线单丝之间的间隙中。
S2、制备绝缘层:在S1制备的导体外挤包交联聚乙烯绝缘层,采用的交联聚乙烯的耐温等级必须在-40℃~90℃之间,这样能承受昼夜温差的变化,同时也能够在酷暑的夏天和严寒的冬天使用,同时也要保证具有良好的电气性能、低吸潮性和优异的机械物理性能。
S3、制备缆芯:将多根制备的导体进行绞合,采用非吸湿性填充物填充在导体内部的间隙中,采用非吸湿性包带绕包在多根导体外侧,构成缆芯。
具体地,所述采用的非吸湿性填充物和非吸湿性包带都经过烘干处理,采用的非吸湿性填充物和非吸湿性包带均在温度为50±5℃的烘箱中预处理24±1小时,接着在干燥器中冷却,然后在温度为20±5℃、湿度为95±4%的环境中放置48小时,使其吸收的水分重量不超过5%。
具体地,所述非吸湿性包带为标称厚度0.2mm的2层非吸湿性无纺布,绕包重叠率≥25%,绕包要求紧密平整,不允许任何位置有漏包及松包现象。
S4、制备防水与防虫害共挤层:在S3制备的缆芯外纵包双面铝塑复合带,通过喇叭模将铝塑复合带收紧到紧贴缆芯的大小,再经过加热装置进行加热,通过加热装置使铝塑复合带的塑面相互黏贴,紧密粘合在一起,构成第一步径向防水层;
双面铝塑复合带包括铝带和包覆在铝带两侧的塑料膜,所述铝带和塑料膜之间不分层,所述双面铝塑复合带的标称厚度为0.3mm,具体地,本实施例所使用的双面铝塑复合带的性能指标参照表一:
表一
缆芯包覆双面铝塑复合带后,采用双层共挤挤出机进行双层共挤,内层采用聚乙烯材料,挤出标称厚度应为2.0mm,作为第二步径向防水层,外层采用尼龙材料,本实施例采用的尼龙材料为尼龙12,所述尼龙12的柔软性、化学稳定性、耐油性、耐磨性均较好,具体的性能参数参照表二,挤出厚度应不小于0.2mm,作为防虫害层;
表二S5、制备外护层:在S4制备的防水与防虫害共挤层外挤包外护层,所述外护层采用聚乙烯或聚氯乙烯材料,本实施例中采用聚乙烯材料制成外护层,具有环保性,无卤、无毒、无味、无重金属,并且具备优良的阻燃性能和很好的机械物理性能,聚乙烯材料的性能参数参照表三:
表三
为了增加电缆的抗压强度,使本实施中的电缆能够适用于多种环境,在步骤S5制备外护套前,制备金属铠装层,所述金属铠装层采用镀锌钢带纵包在所述防水与防虫害共挤层外侧,此种金属铠装层适用于直埋、穿管、隧道敷设,或采用若干根不锈钢丝绕包在防水与防虫害共挤层外侧,此种金属铠装层适用于短距离架空敷设和垂直敷设,保护电缆免受外部机械损伤。
参照图2所示,根据上述防虫害防水电力电缆的生产工艺的制造步骤成产防虫害防水电力电缆的一实施例,包括由若干根导线单丝绞合构成的导体1,所述导线线单丝之间填充阻水材料,在导体1外绕包有阻水带,在阻水带外挤包交联聚乙烯绝缘层2,多根所述导体按照合适的节径比绞合构成缆芯,多根所述导体内部的间隙中填充有非吸湿性填充物3,保证缆芯的美观和圆整,在所述缆芯外依次包覆有非吸湿性包带4、铝塑复合带5、径向防水层6、防虫害层7和外护层8。
以上所述实施例仅是为充分说明本发明而所举的较佳的实施例,本发明的保护范围不限于此。本技术领域的技术人员在本发明基础上所作的等同替代或变换,均在本发明的保护范围之内。本发明的保护范围以权利要求书为准。

Claims (10)

1.一种防虫害防水电力电缆的生产工艺,其特征在于,包括如下步骤:
S1、制备导体:金属杆材在外力的作用下,经过拉伸模具得到导线单丝,以一根导线单丝为中心,将多根导线单丝分层、多次、正反向绞合在中心的导线单丝外侧制成导体,在多层导线单丝之间填充阻水材料,在导体外绕包有阻水带;
S2、制备绝缘层:在S1制备的导体外挤包交联聚乙烯绝缘层;
S3、制备缆芯:将多根制备的导体进行绞合,采用非吸湿性填充物填充在导体内部的间隙中,采用非吸湿性包带绕包在多根导体外侧,构成缆芯;
S4、制备防水与防虫害共挤层:在S3制备的缆芯外纵包双面铝塑复合带,通过喇叭模将铝塑复合带收紧到紧贴缆芯的大小,再经过加热装置进行加热,通过加热装置使铝塑复合带的塑面相互黏贴,紧密粘合在一起,构成第一步径向防水层;
缆芯包覆双面铝塑复合带后,采用双层共挤挤出机进行双层共挤,内层采用聚乙烯材料,挤出标称厚度应为2.0mm,作为第二步径向防水层,外层采用尼龙材料,挤出厚度应不小于0.2mm,作为防虫害层;
S5、制备外护层:在S4制备的防水与防虫害共挤层外挤包外护层。
2.如权利要求1所述的防虫害防水电力电缆的生产工艺,其特征在于,步骤S1中,导线拉丝的过程中,在拉丝模具内添加润滑液,保持拉丝模具内通畅,润滑液的配比浓度为2%~10%。
3.如权利要求2所述的防虫害防水电力电缆的生产工艺,其特征在于,所述润滑液循环使用,温度控制在10℃~65℃之间,并且需要使用折光仪定期测试润滑液的浓度。
4.如权利要求1所述的防虫害防水电力电缆的生产工艺,其特征在于,步骤S1中,任意相邻两层的导线单丝绞合方向相反,绞合在最外层的导线单丝的节径比为12~20,绞合在内层的导线单丝的节径比为20~40。
5.如权利要求1所述的防虫害防水电力电缆的生产工艺,其特征在于,步骤S2中,交联聚乙烯绝缘层的耐温等级在-40℃~90℃之间。
6.如权利要求1所述的防虫害防水电力电缆的生产工艺,其特征在于,步骤S3中,采用的非吸湿性填充物和非吸湿性包带均在温度为50±5℃的烘箱中预处理24±1小时,接着在干燥器中冷却,然后在温度为20±5℃、湿度为95±4%的环境中放置48小时,使其吸收的水分重量不超过5%。
7.如权利要求1所述的防虫害防水电力电缆的生产工艺,其特征在于,步骤S3中,所述非吸湿性包带为标称厚度0.2mm的2层非吸湿性无纺布,绕包重叠率≥25%。
8.如权利要求1所述的防虫害防水电力电缆的生产工艺,其特征在于,步骤S4中,双面铝塑复合带包括铝带和包覆在铝带两侧的塑料膜,所述铝带和塑料膜之间不分层,所述双面铝塑复合带的标称厚度为0.3mm。
9.如权利要求1所述的防虫害防水电力电缆的生产工艺,其特征在于,步骤S5中,所述外护层采用聚乙烯或聚氯乙烯材料。
10.如权利要求1所述的防虫害防水电力电缆的生产工艺,其特征在于,在步骤S5制备外护套前,制备金属铠装层,所述金属铠装层采用镀锌钢带纵包在所述防水与防虫害共挤层外侧,或采用若干根不锈钢丝绕包在防水与防虫害共挤层外侧。
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