CN111681812A - 一种抗核电磁大电流柔软扁电缆 - Google Patents
一种抗核电磁大电流柔软扁电缆 Download PDFInfo
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Abstract
本发明涉及强电扁电缆技术领域,具体涉及一种抗核电磁大电流柔软扁电缆,本发明的扁电缆包括若干个绝缘线芯和设置在绝缘线芯外的护套,所述绝缘线芯包括从内到外设置的导体、导体外挤包的绝缘层、屏蔽层,所述导体为若干个水平排布的紧挨的分导体。本发明的扁电缆可以满足核电磁环境下移动大电流传输和电缆的柔软弯曲要求。
Description
技术领域
本发明涉及强电扁电缆技术领域,具体涉及一种抗核电磁大电流柔软扁电缆。
背景技术
随着抗核磁电气装备的大型化和高功率发展趋势,对电缆提出了越来越高的要求,国内外已有电缆主要是侧重于满足抗核磁要求的仪表、控制、通信、电子传输的弱电电缆,尚无适于恶劣环境下装备移动电源传输大电流所需的抗核电磁柔软型电力电缆。采用通用电缆存在弊端,大规格圆形电缆因电流趋肤效应导体截面有效利用效率很低,多芯成缆外径大,不利于移动装备有限空间使用;扁电缆采用大规格圆导体单独绝缘,芯线间隔布置,除导体截面利用率低外,同时尺寸大、层数多、弯曲困难,不利于散热。
发明内容
为了解决上述问题,本发明旨在通过对扁电缆结构或制造的改进来提升扁电缆的抗核电磁能力、电流传输能力、柔软弯曲度以及环境适应性。
本发明具体采用如下方案:
一种抗核电磁大电流柔软扁电缆,包括电缆线芯和护套,所述护套通过共挤的方式包覆在至少2个并排设置的电缆线芯外侧,所述电缆线芯包括从内到外设置的绝缘线芯和复合屏蔽层,所述绝缘线芯包括从内到外设置的导体、导体外挤包的绝缘层,所述导体为若干个水平排布的紧挨的分导体。
优选的,所述各分导体为结构、大小、材料均相同的导体结构。
优选的,所述复合屏蔽层包括从内到外依次设置的第一导电布绕包层、镀镍铜丝编织层、铝塑复合带绕包层、镀锡铜丝编织层和第二导电布绕包层,各层绕包方向相反。
优选的,所述镀镍铜丝编织层和镀锡铜丝编织层的编织丝径为0.13mm~0.17mm,编织角度为60°~70°,编织密度为90%~95%;所述第一导电布绕包层和第二导电布绕包层的搭盖率为40%~50%。
优选的,所述第一导电布绕包层、铝塑复合带绕包层和第二导电布绕包层的厚度均为0.13mm~0.17mm。
优选的,所述第一导电布绕包层和第二导电布绕包层所用导电布由铜、镍复合金属粉,镀覆在涤纶纤维构成的平纹布带表面构成,铜、镍成分比例限定在5:5~6:4之间,导电布表面电阻不大于0.03Ω。,还包括绕包层,所述绕包层设置于复合屏蔽层和绝缘层之间。
优选的,所述绕包层为多层光滑薄膜重叠绕包而成。
优选的,所述电缆线芯之间存在间隔,间隔被护套填充。
优选的,所述护套选自热塑性聚酯弹性体或聚醚型聚氨酯弹性体。
有益效果:
(1)将导体分割成各份分导体,并排排布,且每份分导体不单独绝缘,直接在排布好的所有分导体外挤包绝缘,如此设置共有三方面的好处:①增加了扁电缆的柔软弯曲度;②整体减小电缆的厚度,方便装盘空间利用;③避免了大截面导体传输电流时因趋肤效应导致导体有效利用截面严重减小的弊端,在电流传输时并联使用可成倍增加每份导体载流量;④各份分割导体不单独绝缘可减小电缆外径和重量,且有利于电缆电流传输时的温升散热,增大载流量。
(2)限定各分导体的结构、大小、材料均相同,进一步保证分导体在传输电流时的并联性能。
(3)本扁电缆采用特殊的复合屏蔽层,磁性材料和非磁性材料复合兼顾高低频下的电屏蔽和磁屏蔽;通过多层反射,使干扰电磁波得到充分减弱从而提高电磁屏蔽效能;采用绕包和编织方式相结合工艺既提高产品柔软度,又增强屏蔽效能。
(4)限定各编织层的丝径、编织角度和密度,限定各导电布绕包层的搭盖率,以及限定相反的绕包方向,进一步增强电缆的屏蔽效能和柔软度。
(5)限定导电布的成分以及表面电阻,是为了防止导电布的电阻过大,限定导电布成分以及最大电阻从而保证屏蔽效果。
(6)在屏蔽层和绝缘层之间设置绕包层,避免屏蔽编织丝端头存在刺入绝缘层形成安全隐患。
(7)绕包层选自多层绕包的光滑薄膜,使屏蔽层和绝缘线芯之间在弯曲时形成滑动。
(8)多个电缆线芯之间存在间隔,间隔被护套填充。也即将多个电缆线芯水平排布后在外层共挤形成护套层,护套填充了多个电缆线芯之间的间隔,使得电缆两边和中间均匀受力,避免多线芯排列在生产牵引中造成大宽度变形导致不平整、弧状或线芯错位叠加。
(9)护套选择热塑性聚酯弹性体(TPE)或聚醚型聚氨酯弹性体(PUR),以满足恶劣的特殊环境工况。TPE具有硫化橡胶的性能,具有突出的机械强度、优良的回弹性和宽广的使用温度,特别是兼具硫化橡胶的性能和热塑性塑料的加工工艺特性。聚氨酯弹性体的性能特点是比重小,富有卓越的弹性,抗拉性和耐磨性优异,具有良好的机械强度、耐油性、耐臭氧性、低温性和柔软性,使用环境温度可达-50℃,聚醚型聚氨酯在淡水、海水或湿度高的环境下具有抗水解性、耐化学品腐蚀,能有效抵抗风雨侵蚀,遇水具有低摩擦性或防粘性,电缆之间相互接触滑动,移动阻力小,特别适宜恶劣工况环境下经常卷绕或移动使用电缆的护套。
综上,本发明的扁电缆可满足核电磁环境下移动大电流传输和柔软弯曲要求,载流量比同等截面单一圆导体提升约25%,弯曲半径可达到3倍的电缆厚度;具备抗核电磁、耐低气压、耐低温、耐日光、耐盐雾、耐霉菌、抗风沙雨雪冰雹等优异性能,能在以下自然和诱发环境条件下正常工作。
附图说明
图1本发明绝缘线芯结构示意图。
图2本发明电缆线芯结构示意图。
图3本发明电缆结构示意图。
图4本发明电缆复合屏蔽层结构示意图。
1-导体;2-绝缘层;3-绕包层;4-复合屏蔽层;4.1-第一导电布绕包层、4.2-镀镍铜丝编织层、4.3-铝塑复合带绕包层、4.4-镀锡铜丝编织层;4.5-第二导电布绕包层;5-护套层;6-电缆线芯;7-绝缘线芯。
具体实施方式
下面结合附图对本发明进行详细说明,以方便本领域技术人员理解本发明,并不构成对本发明的限制。
下面结合附图对本发明进行详细说明,以方便本领域技术人员理解本发明。
如图3所示,本发明实施例中的一种抗核电磁大电流柔软扁电缆,包括并排放置的两个电缆线芯6(见图2)和通过共挤设置在两个电缆线芯6外的护套5,所述电缆线芯6包括从内到外设置的一个绝缘线芯7(见图3和图1)和复合屏蔽层4,绝缘线芯7包括从内到外设置的四个水平排布紧挨的分导体1以及通过共挤包裹在四个分导体1外侧的绝缘层2。绝缘层2采用抗撕裂高强度硅橡胶,耐温高、柔软、抗撕、机械性能优异,耐温等级可达180℃,撕裂强度为38kN/m,绝缘外不必编织玻璃纤维,抗拉强度达9.0MPa,断裂伸长率达480%,邵氏硬度A为70,比重仅1.19g/cm3,均优于行业惯用的硅橡胶。根据GJB1916-94舰船电缆和软线通用规范规定,惯用的硅橡胶抗撕裂强度很差,需要在绝缘外编织玻璃纤维;而GB/T33596-2017规定硅橡胶抗拉强度和断裂伸长率分别为7.0MPa和150%。
上述实施例中各分导体1均是采用直径不大于0.3mm的镀金属铜丝绞合而成,各分导体1结构、大小、材料均相同的导体结构。每份导体不单独绝缘,整体排列的导体排束外挤包绝缘,可整体减小电缆厚度,便于装盘空间利用。
如图4所示,上述所述复合屏蔽层4包括从内到外依次设置的第一导电布绕包层4.1、镀镍铜丝编织层4.2、铝塑复合带绕包层4.3、镀锡铜丝编织层4.4和第二导电布绕包层4.5,各层绕包方向相反,用以增强电缆的结构稳定性。
上述所述镀镍铜丝编织层4.2和镀锡铜丝编织层4.4的编织丝径选自0.13mm~0.17mm,编织角度为60°~70°,编织密度为90%~95%;所述第一导电布绕包层4.1和第二导电布绕包层4.5的搭盖率为40%~50%。
且,复合屏蔽层4的第一导电布绕包层4.1、铝塑复合带绕包层4.3和第二导电布绕包层4.5的厚度选自0.13mm~0.17mm。限定导电布绕包厚度是为了保证电缆的柔软弯曲性能以及屏蔽性能。
上述所述第一导电布绕包层4.3和第二导电布绕包层4.5所用导电布表面电阻不大于0.03Ω。所用导电布均是由铜、镍和涤纶纤维构成,采用复合金属粉均匀镀覆在平纹布带表面。具体来讲,本实施例所用导电布是铜、镍复合金属粉,镀覆在涤纶纤维构成的平纹布带表面。铜、镍成分比例限定在5:5~6:4之间。
如图3所示,上述变电缆中还包括绕包层3,所述绕包层3设置于复合屏蔽层4和绝缘层2之间。所述绕包层3为多层光滑薄膜重叠绕包而成。
上述扁电缆中两个电缆线芯(6)之间存在间隔,间隔距离为1mm~2mm,间隔被护套(5)填充。也即,护套5是通过共挤的方式包覆在两个电缆线芯6的外侧,因采用共挤方式,所以间隔被护套5填实,进一步起到加强筋的作用。
护套5的材料选自热塑性聚酯弹性体(TPE)或聚醚型聚氨酯弹性体(PUR)。TPE具有硫化橡胶的性能,具有突出的机械强度、优良的回弹性和宽广的使用温度,特别是兼具硫化橡胶的性能和热塑性塑料的加工工艺特性。聚氨酯弹性体的性能特点是比重小,富有卓越的弹性,抗拉性和耐磨性优异,具有良好的机械强度、耐油性、耐臭氧性、低温性和柔软性,使用环境温度可达-50℃,聚醚型聚氨酯在淡水、海水或湿度高的环境下具有抗水解性、耐化学品腐蚀,能有效抵抗风雨侵蚀,遇水具有低摩擦性或防粘性,电缆之间相互接触滑动,移动阻力小,特别适宜恶劣工况环境下经常卷绕或移动使用电缆的护套。
试验验证
采用本发明的方法制备一种扁电缆,扁电缆的试验结果:
以上所述实施例仅表达了本发明的几种实施方式,其描述较为具体和详细,但并不能因此而理解为对本发明专利范围的限制。应当指出的是,对于本领域的普通技术人员来说,在不脱离本发明构思的前提下,还可以做出若干变形和改进,这些都属于本发明的保护范围。
Claims (10)
1.一种抗核电磁大电流柔软扁电缆,其特征在于,包括电缆线芯(6)和护套(5),所述护套(5)通过共挤的方式包覆在至少2个并排设置的电缆线芯(6)外侧,所述电缆线芯(6)包括从内到外设置的绝缘线芯(7)和复合屏蔽层(4),所述绝缘线芯(7)包括从内到外设置的导体、导体外挤包的绝缘层(2),所述导体为若干个水平排布的紧挨的分导体(1)。
2.根据权利要求1所述的扁电缆,其特征在于,所述各分导体(1)为结构、大小、材料均相同的导体结构。
3.根据权利要求1所述的扁电缆,其特征在于,所述复合屏蔽层(4)包括从内到外依次设置的第一导电布绕包层(4.1)、镀镍铜丝编织层(4.2)、铝塑复合带绕包层(4.3)、镀锡铜丝编织层(4.4)和第二导电布绕包层(4.5),各层绕包方向相反。
4.根据权利要求3所述的扁电缆,其特征在于,所述镀镍铜丝编织层(4.2)和镀锡铜丝编织层(4.4)的编织丝径为0.13mm~0.17mm,编织角度为60°~70°,编织密度为90%~95%;所述第一导电布绕包层(4.1)和第二导电布绕包层(4.5)的搭盖率为40%~50%。
5.根据权利要求4所述的扁电缆,其特征在于,所述第一导电布绕包层(4.1)、铝塑复合带绕包层(4.3)和第二导电布绕包层(4.5)的厚度均为0.13mm~0.17mm。
6.根据权利要求4所述的扁电缆,其特征在于,所述第一导电布绕包层(4.3)和第二导电布绕包层(4.5)所用导电布由铜、镍复合金属粉镀覆在涤纶纤维构成的平纹布带表面构成,铜、镍成分比例限定在5:5~6:4之间,导电布表面电阻不大于0.03Ω。
7.根据权利要求1所述的扁电缆,其特征在于,还包括绕包层(3),所述绕包层(3)设置于复合屏蔽层(4)和绝缘层(2)之间。
8.根据权利要求5所述的扁电缆,其特征在于,所述绕包层(3)为多层光滑薄膜重叠绕包而成。
9.根据权利要求1所述的扁电缆,其特征在于,所述电缆线芯(6)之间存在间隔,间隔被护套(5)填充。
10.根据权利要求1所述的扁电缆,其特征在于,所述护套(5)选自热塑性聚酯弹性体或聚醚型聚氨酯弹性体。
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