CN111462937A - 抗拉力型电梯屏蔽扁电缆及其制备方法 - Google Patents
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Abstract
本发明公开了一种抗拉力型电梯屏蔽扁电缆及其制备方法,包括呈一排布置且轴线位于同一平面的三个绝缘同轴线、四个绝缘多芯线和两个抗拉钢绞线,所述三个绝缘同轴线外部共同包覆聚氯乙烯发泡层并形成第一线芯体,所述两个绝缘多芯线外部共同包覆聚氯乙烯发泡层并形成第二线芯体,余下所述两个绝缘多芯线外部共同包覆聚氯乙烯发泡层并形成第三线芯体,所述第一线芯体位于中间且左右两侧依次对称设置所述两个抗拉钢绞线、所述第二线芯体和所述第三线芯体并共同形成缆芯,所述缆芯的外部包覆有丁腈聚氯乙烯外护套。该扁电缆机械强度高,抗拉力作用强,耐弯曲性更好,有效提高扁电缆的安全可靠性。
Description
技术领域
本发明涉及电缆技术领域,尤其涉及一种抗拉力型电梯屏蔽扁电缆及其制备方法。
背景技术
扁平电缆是用于移动式电气设备中,适用于频繁弯曲的场合,广泛应用于行车、发电、冶金、运输、机械、电气、矿山等恶劣环境下移动电器设备之间电器连接,各种移动动力装置的电源连接及控制信号照明灯,如快速运行集装箱吊车、起重设备,可行驶大型设备和挖掘机、地面和井下采矿等有较高机械应力的场合,如:港口起重设备、斗轮机等。扁平电缆具有易排列、柔软、弯曲不打结等特点,适用于电梯的动力控制、照明及通讯等功能。建筑物中电梯使用的扁平电缆尺寸长、重量大,施加在电缆中钢绞线的张力增加,随之产生更大的扭矩,使得电缆具有发生扭曲的安全隐患,而且,由于承受较大机械冲击拉力,在扁电缆断面长轴向的两端部局部应力集中,机械强度偏低,扁电缆弯曲时,配置在两端的钢绞线会朝向内侧的绝缘线芯偏移,使得应力集中于绝缘线芯,并容易损伤绝缘线芯,影响扁电缆的安全可靠性。
发明内容
本发明针对现有技术的不足,所要解决的技术问题是提供一种抗拉力型电梯屏蔽扁电缆,机械强度高,抗拉力作用强,耐弯曲性更好,有效提高扁电缆的安全可靠性。同时,还提供抗拉力型电梯屏蔽扁电缆的制备方法。
本发明是通过以下技术方案使上述技术问题得以解决。
抗拉力型电梯屏蔽扁电缆,包括呈一排布置且轴线位于同一平面的三个绝缘同轴线、四个绝缘多芯线和两个抗拉钢绞线,所述三个绝缘同轴线外部共同包覆聚氯乙烯发泡层并形成第一线芯体,所述两个绝缘多芯线外部共同包覆聚氯乙烯发泡层并形成第二线芯体,余下所述两个绝缘多芯线外部共同包覆聚氯乙烯发泡层并形成第三线芯体,所述第一线芯体位于中间且左右两侧依次对称设置所述两个抗拉钢绞线、所述第二线芯体和所述第三线芯体并共同形成缆芯,所述缆芯的外部包覆有丁腈聚氯乙烯外护套。
作为优选,所述两个抗拉钢绞线之间的绞向相反。
作为优选,所述绝缘同轴线包括内导体及所述内导体外部依次包覆有PET缠绕带、硅烷接枝交联低密度聚乙烯内绝缘层、ETFE外绝缘层、金属编织屏蔽层和PTFE绕包层,所述内导体包括中心导体及依次围绕所述中心导体外部绞合的内层导体组和外层导体组,所述内层导体组由若干个内层导体同心绞合构成,所述外层导体组由若干个外层导体同心绞合构成,所述内层导体组和所述外层导体组绞合方向相反,所述内层导体组的绞距小于所述外层导体组绞距。
作为优选,所述硅烷接枝交联低密度聚乙烯内绝缘层厚度大于所述ETFE外绝缘层厚度。
作为优选,所述中心导体、所述内层导体和所述外层导体均为若干镀锡铜单丝束绞构成,所述镀锡铜单丝的直径为0.02mm至0.08mm。
作为优选,所述绝缘多芯线包括绝缘线芯及所述绝缘线芯外部包覆有氟树脂绕包带层,所述绝缘线芯包括中心部的PFA树脂填充芯材及围绕在所述PFA树脂填充芯材外部同心绞合的若干同轴电线,所述同轴电线包括导体及依次包覆在所述导体外部的内绝缘层、金属缠绕屏蔽层和外绝缘层。
作为优选,所述内绝缘层为硅烷接枝交联低密度聚乙烯绝缘层,所述外绝缘层为硅烷接枝交联高密度聚乙烯绝缘层。
作为优选,所述金属缠绕屏蔽层为两种不同直径的镀锡铜单丝混合单向螺旋缠绕构成且螺旋角度为25度至40度,所述两种不同直径的镀锡铜丝的直径比介于0.9至1之间且直径为0.02mm至0.05mm。
作为优选,所述聚氯乙烯发泡层与所述丁腈聚氯乙烯外护套的厚度比为1:1至1:2.5。
抗拉力型电梯屏蔽扁电缆的其制备方法,包括以下步骤:
步骤一:通过绞合工艺分别获得导体和PFA树脂填充芯材;
步骤二:通过缠绕工艺和交联挤包工艺在导体上依次形成内绝缘层、金属缠绕屏蔽层和外绝缘层获得同轴电线;
步骤三:通过绞合工艺将若干同轴电线和PFA树脂填充芯材绞合获得绝缘线芯;
步骤四:通过缠绕工艺在绝缘线芯上包覆氟树脂绕包带层获得绝缘多芯线;
步骤五:通过挤出发泡工艺在两个绝缘多芯线外部形成聚氯乙烯发泡层获得第二线芯体或第三线芯体;
步骤六:通过绞合工艺获得内导体;
步骤七:通过缠绕工艺和挤包工艺在内导体上依次形成PET缠绕带、硅烷接枝交联低密度聚乙烯内绝缘层、ETFE外绝缘层、金属编织屏蔽层和PTFE绕包层获得绝缘同轴线;
步骤八:通过挤出发泡工艺在三个绝缘同轴线外部形成聚氯乙烯发泡层获得第一线芯体;
步骤九:通过绞合工艺获得抗拉钢绞线;
步骤十:将第一线芯体、第二线芯体、第三线芯体和两个抗拉钢绞线并列布置成缆芯;
步骤十一:通过挤包工艺在缆芯上形成丁腈聚氯乙烯外护套,制备出扁电缆。
本发明的有益效果:
1.绝缘同轴线和绝缘多芯线分别包覆聚氯乙烯发泡层形成独立的第一线芯体、第二线芯体和第三线芯体,并通过两个抗拉钢绞线分隔并共同包覆丁腈聚氯乙烯外护套,使得抗拉钢绞线与邻近的绝缘同轴线和绝缘多芯线之间保持多层树脂层间隔,减缓扁电缆断面长轴向的两侧端部局部应力集中,提高了机械结构强度的同时,大大提高了抗拉力性能,在扁电缆弯曲时,能够有效的避免抗拉钢绞线朝向邻近芯线偏移,消除损伤邻近芯线带来的安全隐患。两个抗拉钢绞线之间的绞向相反,电缆在弯曲及扭转过程中,有助于消减扭矩力,提高安全可靠性。
2.丁腈聚氯乙烯外护套的拉伸强度和伸长率更大,在经受长时间的弯曲、扭转后,也不易出现撕裂,对聚氯乙烯发泡层形成有效保护,有益于提高耐弯曲和抗扭转性能。
3.绝缘线芯为PFA树脂填充芯材和同轴电线同心绞合,在PFA树脂填充芯材和同轴电线之间形成有空隙,柔韧性好,抗拉强度增大,不易断线,有效降低扭转弯曲过程中的扭矩力,提高抗弯曲性和抗扭转性。
4.中心导体、内层导体和外层导体为直径0.02mm至0.08mm镀锡铜单丝束绞构成,提高耐弯曲性,抗拉强度大,保证良好的长距离信号传送的电气特性,内层导体组和外层导体组采用同心复绞能够降低内层导体和外层导体束绞时易出现的松散性,而且,内层导体组和外层导体组绞合方向相反,内层导体组的绞距小于所述外层导体组绞距,能够降低扭转应力,抑制单丝变形,提高抗拉强度,不易发生断裂,兼具实现良好的电气特性、耐弯曲和耐弯曲性能。与内层导体、外层导体具有相同抗拉强度相比较,内层导体的抗拉强度大于外层导体的抗拉强度,则有助于提高电缆的耐弯曲特性。
5.ETFE外绝缘层具有优异的耐磨耗性、耐弯曲性和耐热性,硅烷接枝交联低密度聚乙烯内绝缘层静摩擦系数小、柔软性更好,硅烷接枝交联低密度聚乙烯内绝缘层的厚度大于ETFE外绝缘层,通过优化厚度比例,使得绝缘层在获得优异的耐磨耗性前提下,具备更好的耐弯曲性和柔韧性,耐久使用。
6.金属编织屏蔽层能够有效的抑制内部的信号或噪音泄漏至外部及抑制来自外部信号的干扰,同时,采用PTFE绕包层,摩擦系数小,减少金属编织屏蔽层应力集中,降低弯曲时的扭矩力,提高耐挠曲性和耐久使用性。
附图说明
图1为本申请具体实施方式的断面结构示意图;
图2为本申请具体实施方式的绝缘同轴线断面结构示意图;
图3为本申请具体实施方式的绝缘多芯线断面结构示意图。
图中:1-绝缘同轴线,11-内导体,111-中心导体,112-内层导体,113-外层导体,12-PET缠绕带,13-硅烷接枝交联低密度聚乙烯内绝缘层,14-ETFE外绝缘层,15-金属编织屏蔽层,16-PTFE绕包层,2-绝缘多芯线,21-氟树脂绕包带层,22-PFA树脂填充芯材,23-同轴电线,231-导体,232-内绝缘层,233-金属缠绕屏蔽层,234-外绝缘层,3-抗拉钢绞线,4-聚氯乙烯发泡层,5-第一线芯体,6-第二线芯体,7-第三线芯体,8-丁腈聚氯乙烯外护套。
具体实施方式
下面结合附图并通过具体实施方式来进一步说明本发明的技术方案。
如图1所示,本发明实施例的抗拉力型电梯屏蔽扁电缆,包括呈一排布置且轴线位于同一平面的三个绝缘同轴线1、四个绝缘多芯线2和两个抗拉钢绞线3,所述三个绝缘同轴线1外部共同包覆聚氯乙烯发泡层4并形成第一线芯体5,所述两个绝缘多芯线2外部共同包覆聚氯乙烯发泡层4并形成第二线芯体6,余下所述两个绝缘多芯线2外部共同包覆聚氯乙烯发泡层4并形成第三线芯体7,所述第一线芯体5位于中间且左右两侧依次对称设置所述两个抗拉钢绞线3、所述第二线芯体6和所述第三线芯体7并共同形成缆芯,所述缆芯的外部包覆有丁腈聚氯乙烯外护套8。所述抗拉钢绞线3比如为镀锌钢丝或不锈钢丝绞线,优选的,所述两个抗拉钢绞线3之间的绞向相反,用于消减扭矩力。进一步的,所述聚氯乙烯发泡层4与所述丁腈聚氯乙烯外护套8的厚度比为1:1至1:2.5。
如图2所示,在一个具体的实施例中,所述绝缘同轴线1包括内导体11,所述内导体11包括中心导体111及依次围绕所述中心导体111外部绞合的内层导体组和外层导体组,所述内层导体组由若干个内层导体112同心绞合构成,所述外层导体组由若干个外层导体113同心绞合构成,所述内层导体组和所述外层导体组绞合方向相反,所述内层导体组的绞距小于所述外层导体组绞距。具体的说,所述中心导体111、所述内层导体112和所述外层导体113均为若干镀锡铜单丝束绞构成,所述镀锡铜单丝的直径为0.02mm至0.08mm。
所述内导体11外部依次包覆有PET缠绕带12、硅烷接枝交联低密度聚乙烯内绝缘层13、ETFE外绝缘层14、金属编织屏蔽层15和PTFE绕包层16。优选的,所述硅烷接枝交联低密度聚乙烯内绝缘层13厚度大于所述ETFE外绝缘层14厚度。在一个实施方式中,所述PET缠绕带12为三层搭盖缠绕结构且搭盖率不小于60%。在一个实施方式中,所述金属屏蔽层15为内层镀锡铜单丝和外层镀锡铜单丝互为逆向螺旋缠绕编织构成,所述内层镀锡铜单丝直径小于所述外层镀锡铜单丝直径,比如所述内层镀锡铜单丝直径为0.08mm至0.12mm,所述外层镀锡铜单丝直径为0.1mm至0.15mm。在一个实施方式中,PTFE绕包层16为间隙绕包结构且绕距为带宽的2至4倍。
如图3所示,所述绝缘多芯线2包括绝缘线芯及所述绝缘线芯外部包覆有氟树脂绕包带层21,比如,氟树脂绕包带层21可采用PTFE、PFA、FEP或ETFE树脂层。所述绝缘线芯包括中心部的PFA树脂填充芯材22及围绕在所述PFA树脂填充芯材22外部同心绞合的若干同轴电线23,所述同轴电线23包括导体231及依次包覆在所述导体231外部的内绝缘层232、金属缠绕屏蔽层233和外绝缘层234。具体的说,所述导体231为若干镀锡铜单丝绞合构成。在一个实施方式中,所述内绝缘层232为硅烷接枝交联低密度聚乙烯绝缘层,所述外绝缘层234为硅烷接枝交联高密度聚乙烯绝缘层,进一步的说,所述内绝缘层232的厚度为0.025mm至0.08mm,所述外绝缘层234的厚度为0.025mm至0.05mm。在一个实施方式中,所述金属缠绕屏蔽层233为两种不同直径的镀锡铜单丝混合单向螺旋缠绕构成且螺旋角度为25度至40度,所述两种不同直径的镀锡铜丝的直径比介于0.9至1之间且直径为0.02mm至0.05mm。
抗拉力型电梯屏蔽扁电缆的其制备方法,包括以下步骤:
步骤一:通过绞合工艺分别获得导体和PFA树脂填充芯材;
步骤二:通过缠绕工艺和交联挤包工艺在导体上依次形成内绝缘层、金属缠绕屏蔽层和外绝缘层获得同轴电线;
步骤三:通过绞合工艺将若干同轴电线和PFA树脂填充芯材绞合获得绝缘线芯;
步骤四:通过缠绕工艺在绝缘线芯上包覆氟树脂绕包带层获得绝缘多芯线;
步骤五:通过挤出发泡工艺在两个绝缘多芯线外部形成聚氯乙烯发泡层获得第二线芯体或第三线芯体;
步骤六:通过绞合工艺获得内导体;
步骤七:通过缠绕工艺和挤包工艺在内导体上依次形成PET缠绕带、硅烷接枝交联低密度聚乙烯内绝缘层、ETFE外绝缘层、金属编织屏蔽层和PTFE绕包层获得绝缘同轴线;
步骤八:通过挤出发泡工艺在三个绝缘同轴线外部形成聚氯乙烯发泡层获得第一线芯体;
步骤九:通过绞合工艺获得抗拉钢绞线;
步骤十:将第一线芯体、第二线芯体、第三线芯体和两个抗拉钢绞线并列布置成缆芯;
步骤十一:通过挤包工艺在缆芯上形成丁腈聚氯乙烯外护套,制备出扁电缆。
本发明是通过实施例进行描述的,本领域技术人员知悉,在不脱离本发明的精神和范围的情况下,可以对这些特征和实施例进行各种改变或等效替换。另外,在本发明的指导下,可以对这些特征和实施例进行修改以适应具体的情况及材料而不脱离本发明的精神和范围。因此,本发明不受此处所公开的具体实施例的限制,所有落入本申请的权利要求内的实施例都属于本发明保护的范围。
Claims (10)
1.抗拉力型电梯屏蔽扁电缆,其特征是:包括呈一排布置且轴线位于同一平面的三个绝缘同轴线(1)、四个绝缘多芯线(2)和两个抗拉钢绞线(3),所述三个绝缘同轴线(1)外部共同包覆聚氯乙烯发泡层(4)并形成第一线芯体(5),所述两个绝缘多芯线(2)外部共同包覆聚氯乙烯发泡层(4)并形成第二线芯体(6),余下所述两个绝缘多芯线(2)外部共同包覆聚氯乙烯发泡层(4)并形成第三线芯体(7),所述第一线芯体(5)位于中间且左右两侧依次对称设置所述两个抗拉钢绞线(3)、所述第二线芯体(6)和所述第三线芯体(7)并共同形成缆芯,所述缆芯的外部包覆有丁腈聚氯乙烯外护套(8)。
2.根据权利要求1所述的抗拉力型电梯屏蔽扁电缆,其特征是:所述两个抗拉钢绞线(3)之间的绞向相反。
3.根据权利要求1所述的抗拉力型电梯屏蔽扁电缆,其特征是:所述绝缘同轴线(1)包括内导体(11)及所述内导体(11)外部依次包覆有PET缠绕带(12)、硅烷接枝交联低密度聚乙烯内绝缘层(13)、ETFE外绝缘层(14)、金属编织屏蔽层(15)和PTFE绕包层(16),所述内导体(11)包括中心导体(111)及依次围绕所述中心导体(111)外部绞合的内层导体组和外层导体组,所述内层导体组由若干个内层导体(112)同心绞合构成,所述外层导体组由若干个外层导体(113)同心绞合构成,所述内层导体组和所述外层导体组绞合方向相反,所述内层导体组的绞距小于所述外层导体组绞距。
4.根据权利要求3所述的抗拉力型电梯屏蔽扁电缆,其特征是:所述硅烷接枝交联低密度聚乙烯内绝缘层(13)厚度大于所述ETFE外绝缘层(14)厚度。
5.根据权利要求3所述的抗拉力型电梯屏蔽扁电缆,其特征是:所述中心导体(111)、所述内层导体(112)和所述外层导体(113)均为若干镀锡铜单丝束绞构成,所述镀锡铜单丝的直径为0.02mm至0.08mm。
6.根据权利要求1所述的抗拉力型电梯屏蔽扁电缆,其特征是:所述绝缘多芯线(2)包括绝缘线芯及所述绝缘线芯外部包覆有氟树脂绕包带层(21),所述绝缘线芯包括中心部的PFA树脂填充芯材(22)及围绕在所述PFA树脂填充芯材(22)外部同心绞合的若干同轴电线(23),所述同轴电线(23)包括导体(231)及依次包覆在所述导体(231)外部的内绝缘层(232)、金属缠绕屏蔽层(233)和外绝缘层(234)。
7.根据权利要求6所述的抗拉力型电梯屏蔽扁电缆,其特征是:所述内绝缘层(232)为硅烷接枝交联低密度聚乙烯绝缘层,所述外绝缘层(234)为硅烷接枝交联高密度聚乙烯绝缘层。
8.根据权利要求6所述的抗拉力型电梯屏蔽扁电缆,其特征是:所述金属缠绕屏蔽层(233)为两种不同直径的镀锡铜单丝混合单向螺旋缠绕构成且螺旋角度为25度至40度,所述两种不同直径的镀锡铜丝的直径比介于0.9至1之间且直径为0.02mm至0.05mm。
9.根据权利要求1所述的抗拉力型电梯屏蔽扁电缆,其特征是:所述聚氯乙烯发泡层(4)与所述丁腈聚氯乙烯外护套(8)的厚度比为1:1至1:2.5。
10.抗拉力型电梯屏蔽扁电缆的其制备方法,其特征是:包括以下步骤:
步骤一:通过绞合工艺分别获得导体和PFA树脂填充芯材;
步骤二:通过缠绕工艺和交联挤包工艺在导体上依次形成内绝缘层、金属缠绕屏蔽层和外绝缘层获得同轴电线;
步骤三:通过绞合工艺将若干同轴电线和PFA树脂填充芯材绞合获得绝缘线芯;
步骤四:通过缠绕工艺在绝缘线芯上包覆氟树脂绕包带层获得绝缘多芯线;
步骤五:通过挤出发泡工艺在两个绝缘多芯线外部形成聚氯乙烯发泡层获得第二线芯体或第三线芯体;
步骤六:通过绞合工艺获得内导体;
步骤七:通过缠绕工艺和挤包工艺在内导体上依次形成PET缠绕带、硅烷接枝交联低密度聚乙烯内绝缘层、ETFE外绝缘层、金属编织屏蔽层和PTFE绕包层获得绝缘同轴线;
步骤八:通过挤出发泡工艺在三个绝缘同轴线外部形成聚氯乙烯发泡层获得第一线芯体;
步骤九:通过绞合工艺获得抗拉钢绞线;
步骤十:将第一线芯体、第二线芯体、第三线芯体和两个抗拉钢绞线并列布置成缆芯;
步骤十一:通过挤包工艺在缆芯上形成丁腈聚氯乙烯外护套,制备出扁电缆。
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