CN112037972B - 一种燃烧性能a级柔性防火电缆及其制备工艺 - Google Patents
一种燃烧性能a级柔性防火电缆及其制备工艺 Download PDFInfo
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Abstract
本发明公开了一种燃烧性能A级柔性防火电缆,从内至外包括缆芯、保护层和金属护层;所述缆芯包括多根绝缘线芯绞合而成;所述绝缘线芯之间填充有填充材料形成具有圆形截面的缆芯;所述绝缘线芯包括导体以及包覆在导体外部的绝缘层;所述绝缘层为热释放值低于2.0MJ/kg的绝缘材料;所述填充材料为热释放值低于2.0MJ/kg无机纤维。本发明通过使用热释放值低于2.0MJ/kg的绝缘材料和填充材料制备电缆,确保了电缆的热释放值低于2.0MJ/kg,满足了燃烧性能A级的要求,同时满足耐火性能要求。
Description
技术领域
本发明涉及电缆,尤其涉及一种燃烧性能A级柔性防火电缆及其制备工艺。
背景技术
防火电缆是一种应用于应急系统的特种电缆,保证在火焰的条件下给应急设备连续供电,达到灭火或抢救人员或财产的目的。随着人们对火灾的关注程度越来越高,国内对建筑的防火设计要求越来越高。公安部也出台了相应规范,如《建筑高度大于250米民用建筑防火设计加强性技术要求(试行)》中第二十五条,消防供配电线路应符合下列规定,消防电梯和辅助疏散电梯的供电电线电缆应采用燃烧性能为A级、耐火时间不小于3.0h的耐火电线电缆。国家强制性规范《建筑设计防火规范》对电缆的耐火性能提出了明确而具体的要求。国内消防验收政策也进行了改革,建设工程消防设计审查验收主体由公安消防部门调整为住房和城乡建设主管部门。
现有的能满足燃烧性能A级要求的电缆有BTTZ电缆,该电缆采用氧化镁粉末为无机绝缘材料隔离导体与护套,该结构硬度大,俗称刚性电缆,存在接头多、易吸潮、难施工等问题,因此需开发一种燃烧性能A级的柔性防火电缆。
发明内容
本发明的目的是提供一种燃烧性能A级柔性防火电缆及其制备工艺。
实现本发明目的的第一个技术方案是:一种燃烧性能A级柔性防火电缆,从内至外包括缆芯、保护层和金属护层;所述缆芯包括多根绝缘线芯绞合而成;所述绝缘线芯之间填充有填充材料形成具有圆形截面的缆芯;所述绝缘线芯包括导体以及包覆在导体外部的绝缘层;
所述绝缘层可以为一种绝缘材料,也可以为多种绝缘材料复合,且任何一种绝缘材料的热释放值均低于2.0MJ/kg;所述填充材料为热释放值低于2.0MJ/kg无机纤维;所述保护层为热释放值低于2.0MJ/kg的内护绕包材料。
所述绝缘层为热释放值低于2.0MJ/kg的云母带,单层厚度不超过0.25mm,重叠率不低于30%;所述绝缘层采用加强材料加强;所述加强材料为玻纤;所述玻纤在每平方厘米云母带中经线数量不低于28根;纬线数量不低于10根。
所述云母带中云母含量按重量计算不低于60%,挥发物含量按重量计算不超过0.8%,胶黏剂含量按重量计算不超过10%;所述粘胶剂采用有机硅树脂。
所述填充材料中无机纤维的单丝丝径不超过20μm,含水率不超过0.5%。
所述无机纤维采用膨化浸润剂浸润;所述膨化浸润剂成分及所占比例,去离子水91%、硅烷偶联剂3%、环氧树脂3%和表面活性剂3%。
所述保护层为玻纤带或玄武岩纤维带。
所述金属护层为波纹铜或铜合金管;所述波纹铜所用铜带采用GB/T 2059-2017规定T2或TU2的铜带;所述铜合金管所用铜合金带需符合GB/T 2059-2017的规定。
一种上述的燃烧性能A级柔性防火电缆的制备工艺,包括以下步骤:
步骤一、选择导体;按GB/T 3956中规定的第一类和第二类的要求选择导体;
步骤二、预处理绝缘材料;将绝缘材料放在真空烘箱中干燥,除去多余的水分和溶剂等残余物;
步骤三、制备绝缘线芯;在导体外绕包预处理过的绝缘材料形成绝缘层;
步骤四、成缆制备缆芯;将绝缘线芯成缆,成缆时填充填充材料;
步骤五、在缆芯外绕包保护层;
步骤六、在保护层外氩弧焊金属护层,并在焊后轧纹。
所述步骤二中真空烘箱干燥条件为烘干温度100℃~120℃,气压-0.02MPa~-0.03MPa,时间≥12h。
所述步骤六氩弧焊金属护层时,焊缝处强度不低于母材的80%。
采用了上述技术方案,本发明具有以下的有益效果:
(1)本发明通过使用热释放值低于2.0MJ/kg的柔性绝缘材料、填充材料和内护绕包材料制备电缆,确保了电缆整体的热释放值低于2.0MJ/kg,满足了燃烧性能A级的要求。
(2)本发明的绝缘层采用热释放值低于2.0MJ/kg的云母带,单层厚度不超过0.25mm,重叠率不低于30%。云母带采用玻纤加强,每平方厘米云母带中加强玻纤经线数量不低于28,纬线数量不低于10,这样保证云母带中云母粉的稳定,防止生产过程中以及后期电缆使用中受到冲击震动时云母粉脱落。
(3)本发明的云母带中云母含量按重量计算不低于60%,挥发物含量按重量计算不超过0.8%,胶黏剂含量按重量计算不超过10%,保证了电缆释放的热量不超过2.0MJ/kg,且以有机硅树脂作为胶黏剂,稳定性好、耐高温、不析碳、耐候、耐潮湿性、电绝缘性好。
(4)本发明通过使用无机纤维作为填充材料能有效提高防火性能,且单丝丝径不超过20μm,含水率不超过0.5%,长期放置于自然条件下吸水率不超过0.5%,不含水不吸潮,保证电缆长期使用后绝缘电阻≥100MΩ·km,并通过膨化浸润剂浸润无机纤维,保证无机纤维膨化后的使用强度,不易断丝,不会因纤维刺入绝缘层而降低绝缘电阻;且膨化无机纤维易分布于缆芯周边,更好的起到缓冲作用,防止绝缘线芯与金属护层发生损伤。
(5)本发明的保护层采用玻纤带或玄武岩纤维带,不燃、耐高温、耐火,高温火焰下仍具有一定的强度,起到固定绝缘线芯的作用,防止电缆遇到冲击、震动时发生线芯松散,增强了电缆火焰下的抗冲击、震动性能。
(6)本发明的电缆所用金属护套为波纹铜或铜合金管,所用铜带应采用GB/T2059-2017规定T2或TU2的铜带,所用铜合金带应采符合GB/T 2059-2017相应规定。铜带或铜合金带熔点高,火焰下不会融化,起到很好的挡火和挡水作用,防止火焰或水汽直接与绝缘线芯接触。
(7)本发明在制备时对绝缘材料进行预处理,对绝缘材料进行干燥处理,有效降低绝缘材料中有机物含量,进而降低绝缘材料的热释放值,确保满足燃烧性能A的要求。
(8)本发明轧纹工艺提高了电缆的柔性,轧纹作为缓冲区,保证电缆弯曲时铜管不开裂,拉直时可恢复原状,不会使铜管变瘪,弯曲时不会形成尖锐处,不会刺伤绝缘层。
附图说明
为了使本发明的内容更容易被清楚地理解,下面根据具体实施例并结合附图,对本发明作进一步详细的说明,其中
图1为本发明的结构示意图。
图2为电缆常用绝缘材料热值数据。
附图中标号为:
缆芯1,绝缘线芯1-1、导体1-1-1、绝缘层1-1-2、填充材料1-2、保护层2、金属护层3。
具体实施方式
(实施例1)
见图1,本实施例的一种燃烧性能A级柔性防火电缆,从内至外包括缆芯1、保护层2和金属护层3;所述缆芯1包括多根绝缘线芯1-1绞合而成;所述绝缘线芯1-1之间填充有填充材料1-2形成具有圆形截面的缆芯1;所述绝缘线芯1-1包括导体1-1-1以及包覆在导体1-1-1外部的绝缘层1-1-2。
所述绝缘层1-1-2可以为一种绝缘材料,也可以为多种绝缘材料复合,且任何一种绝缘材料的热释放值均低于2.0MJ/kg;见图2,现在的常用绝缘材料中,满足热释放值低于2.0MJ/kg的材料仅有氧化镁和云母带,但氧化镁为刚性绝缘材料,不适于作为柔性电缆的制备因此,绝缘层1-1-2采用热释放值均低于2.0MJ/kg的云母带,单层厚度不超过0.25mm,重叠率不低于30%;云母带采用玻纤加强;每平方厘米云母带中加强玻纤经线数量不低于28,纬线数量不低于10,这样保证云母带中云母粉的稳定,防止生产过程中以及后期电缆使用中受到冲击震动时云母粉脱落。
云母带中云母含量按重量计算不低于60%,挥发物含量按重量计算不超过0.8%,胶黏剂含量按重量计算不超过10%,保证了电缆释放的热量不超过2.0MJ/kg,且以有机硅树脂作为胶黏剂,稳定性好、耐高温、不析碳、耐候、耐潮湿性、电绝缘性好。
填充材料1-2为热释放值低于2.0MJ/kg无机纤维,单丝丝径不超过20μm,含水率不超过0.5%,长期放置于自然条件下吸水率不超过0.5%,不含水不吸潮,保证电缆长期使用后绝缘电阻≥100MΩ·km。
填充材料1-2采用膨化浸润剂浸润,膨化浸润剂成分包括去离子水、硅烷偶联剂、环氧树脂和表面活性剂。通过膨化后无机纤维的使用强度,不易断丝,不会因纤维刺入绝缘层而降低绝缘电阻;且膨化无机纤维易分布于缆芯周边,更好的起到缓冲作用,防止绝缘线芯与金属护层发生损伤。
保护层2采用玻纤带或玄武岩纤维带,不燃、耐高温、耐火,高温火焰下仍具有一定的强度,起到固定绝缘线芯1-1的作用,防止电缆遇到冲击、震动时发生绝缘线芯1-1松散,增强了电缆火焰下的抗冲击、震动性能。
为保证电缆通过BS 6387:2013、BS 8491:2008以及GB/T 19216.21-2003规定的耐火、振动和喷淋试验,金属护层3为波纹铜或铜合金管,其中波纹铜所用铜带采用GB/T2059-2017规定T2或TU2的铜带;铜合金管所用铜合金带需符合GB/T 2059-2017的规定;铜带或铜合金带熔点高,火焰下不会融化,起到很好的挡火和挡水作用,防止火焰或水汽直接与绝缘线芯接触。
本发明还包括一种燃烧性能A级柔性防火电缆的制备工艺,用于生产上述燃烧性能A级柔性防火电缆,包括以下步骤:
步骤一、按GB/T 3956中规定的第一类和第二类的要求选择导体1-1-1,其中,25平方及以下导体1-1-1不紧压,35平方及以上导体1-1-1紧压,紧压系数不大于0.90。
步骤二、预处理绝缘材料;具体方法为:将绝缘材料放在真空烘箱中干燥,除去多余的水分和溶剂等残余物;其中,真空烘箱干燥条件为烘干温度100℃~120℃,气压-0.02MPa~-0.03MPa,时间≥12h;干燥处理后的绝缘材料应在12h内使用完毕;通过对绝缘材料进行干燥处理,有效降低绝缘材料中有机物含量,进而降低绝缘材料的热释放值,确保满足燃烧性能A的要求。
步骤三、制备绝缘线芯1-1;具体为:用绕包机在导体1-1-1外绕包预处理过的绝缘材料形成绝缘层1-1-2;绕包时,每两层一个方向,先左向后右向,每一绕包层控制带材重叠率不低于30%,绕包层应平整、不起皱。
步骤四、成缆制备缆芯1;将绝缘线芯1-1在成缆机上成缆,成缆时填充填充材料1-2;填充应饱满、均匀,并对绝缘线芯1-1间绝缘电阻进行测试,满足绝缘电阻≥100MΩ·km后进行下一步。
步骤五、在缆芯1外绕包保护层2;具体为:绕包两层不燃性玄武岩带材作为保护层2,一层左向一层右向,每一绕包层控制带材重叠率不低于30%,绕包层应平整、不起皱。
步骤六、在保护层2外氩弧焊金属护层3;具体为:根据缆芯1外径选择合适的铜或铜合金带宽度,以纵包、缝口对焊的加工方式,阻挡火焰或者水进入缆芯1;调节好焊接电流和角度进行焊接,不能出现漏焊或虚焊,焊缝处强度不低于母材的80%,同时金属护层3焊接后应进行浸水试验;焊后轧纹,轧纹节距均匀,通过轧纹工艺提高了电缆的柔性,轧纹作为缓冲区,保证电缆弯曲时铜管不开裂,拉直时可恢复原状,不会使铜管变瘪,弯曲时不会形成尖锐处,不会刺伤绝缘层。
以上的具体实施例,对本发明的目的、技术方案和有益效果进行了进一步详细说明,所应理解的是,以上仅为本发明的具体实施例而已,并不用于限制本发明,凡在本发明的精神和原则之内,所做的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (6)
1.一种燃烧性能A级柔性防火电缆,其特征在于:从内至外包括缆芯(1)、保护层(2)和金属护层(3);所述缆芯(1)包括多根绝缘线芯(1-1)绞合而成;所述绝缘线芯(1-1)之间填充有填充材料(1-2)形成具有圆形截面的缆芯(1);所述绝缘线芯(1-1)包括导体(1-1-1)以及包覆在导体(1-1-1)外部的绝缘层(1-1-2);所述绝缘层(1-1-2)可以为一种绝缘材料,也可以为多种绝缘材料复合,且任何一种绝缘材料的热释放值均低于2.0MJ/kg;所述填充材料(1-2)为热释放值低于2.0MJ/kg无机纤维;所述保护层(2)为热释放值低于2.0MJ/kg的内护绕包材料;所述绝缘层(1-1-2)为热释放值低于2.0MJ/kg的云母带,单层厚度不超过0.25mm,重叠率不低于30%;所述绝缘层(1-1-2)采用加强材料加强;所述加强材料为玻纤;所述玻纤在每平方厘米云母带中经线数量不低于28根,纬线数量不低于10根;所述云母带中云母含量按重量计算不低于60%,挥发物含量按重量计算不超过0.8%,胶黏剂含量按重量计算不超过10%;所述填充材料(1-2)中无机纤维的单丝丝径不超过20µ m,含水率不超过0.5%;长期放置于自然条件下吸水率不超过0.5%,不含水不吸潮,保证电缆长期使用后绝缘电阻≥100MΩ·km;所述无机纤维采用膨化浸润剂浸润;所述膨化浸润剂成分及所占比例,去离子水91%、硅烷偶联剂3%、环氧树脂3%和表面活性剂3%。
2.根据权利要求1所述的一种燃烧性能A级柔性防火电缆,其特征在于:所述保护层(2)为玻纤带或玄武岩纤维带。
3.根据权利要求1所述的一种燃烧性能A级柔性防火电缆,其特征在于:所述金属护层(3)为波纹铜或铜合金管;所述波纹铜所用铜带采用GB/T 2059-2017规定T2或TU2的铜带;所述铜合金管所用铜合金带需符合GB/T 2059-2017的规定。
4.一种绿色建筑用 如权利要求1所述的燃烧性能A级柔性防火电缆的制备工艺,其特征在于,包括以下步骤:
步骤一、选择导体(1-1-1);按GB/T 3956中规定的第一类和第二类的要求选择导体(1-1-1);
步骤二、预处理绝缘材料;将绝缘材料放在真空烘箱中干燥,除去多余的水分和溶剂等残余物;
步骤三、制备绝缘线芯(1-1);在导体(1-1-1)外绕包预处理过的绝缘材料形成绝缘层(1-1-2);
步骤四、成缆制备缆芯(1);将绝缘线芯成缆,成缆时填充填充材料(1-2);
步骤五、在缆芯(1)外绕包保护层(2);
步骤六、在保护层(2)外氩弧焊金属护层(3),并在焊后轧纹。
5.根据权利 要求4所述的一种燃烧性能A级柔性防火电缆的制备工艺,其特征在于:所述步骤二中真空烘箱干燥条件为烘干温度100℃~120℃,气压-0.02MPa~-0.03MPa,时间≥12h。
6.根据权利 要求5所述的一种燃烧性能A级柔性防火电缆的制备工艺,其特征在于:所述步骤六氩弧焊金属护层(3)时,焊缝处强度不低于母材的80%。
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