CN112248567A - 一种电缆绕包层用复合膜及其制备方法 - Google Patents

一种电缆绕包层用复合膜及其制备方法 Download PDF

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CN112248567A
CN112248567A CN202010957079.2A CN202010957079A CN112248567A CN 112248567 A CN112248567 A CN 112248567A CN 202010957079 A CN202010957079 A CN 202010957079A CN 112248567 A CN112248567 A CN 112248567A
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film
parts
montmorillonite
layer
composite
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CN112248567B (zh
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胡广全
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Hangzhou Keneng New Material Technology Co ltd
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Hangzhou Keneng New Material Technology Co ltd
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Priority to US17/129,840 priority patent/US11623435B2/en
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Abstract

本申请公开了一种电缆绕包层用复合膜及其制备方法。一种电缆绕包层用复合膜，包括与电缆绝缘层接触的PE膜层、复合于PE膜层上的PET膜层、复合于PET膜层上的铝箔层以及设于PET膜层与铝箔层之间的粘结层；所述PE膜层由包含以下重量份的原料制成：熔融指数为0.9‑1.1g/10min、密度为0.920‑0.922g/cm3的LLDPE40‑45份，熔融指数为1.9‑2.1g/10min、密度为0.917‑0.920g/cm3的m‑LLDPE35‑40份以及乙烯‑醋酸乙烯酯共聚物15‑25份。采用本申请的复合膜对导体进行包覆时，包覆后的导体不易发生松散、走位或相对偏移的现象，具有较好的包覆效果。

Description

一种电缆绕包层用复合膜及其制备方法
技术领域
本申请涉及复合材料领域，更具体地说，它涉及一种电缆绕包层用复合膜及其制备方法。
背景技术
电缆是一种电能或信号传输装置，其通常是由几根或几组导线绞合而成的类似绳索的结构，每组导线之间相互绝缘，并常围绕着一根中心扭成，整个外包面有高度绝缘的覆盖层。根据图1的电缆剖面图所示，电缆包括至少一根导体1，导体1外包覆有耐火层2，耐火层2外包覆有绝缘层3，绝缘层3外设置有绕包层5，绕包层5将几根包覆有耐火层2和绝缘层3的导体1包覆在内，绕包层5和绝缘层3之间填充有由耐火填料形成的填充层4，绕包层5外包覆有保护套层6。
电缆的绝缘层材料一般采用PVC、PE等，绝缘层的目的是保证在正常情况下电缆的电性能以及对耐火层的保护作用；为了将几根导体包覆成缆，需要采用玻璃丝带、PVC带、无纺布带或云母带等材料，对导体进行绕包紧固，以形成绕包层。但是这种绕包材料仅仅通过缠绕的方式对导体进行包覆，绕包时需要考虑绕包节距、绕包角度、绕包张力等因素，这就对绕包工艺有较高的要求，当绕包层的紧固度过低时，包覆后导体易松散，容易发生走位或相对偏移的现象，使得包覆效果不佳。因此，需要一种新的绕包层材料。
发明内容
为了提高绕包层材料的包覆效果，本申请提供一种电缆绕包层用复合膜及其制备方法。
第一方面，本申请提供一种电缆绕包层用复合膜，采用如下的技术方案：
一种电缆绕包层用复合膜，包括与电缆绝缘层接触的PE膜层、复合于PE膜层上的PET膜层、复合于PET膜层上的铝箔层以及设于PET膜层与铝箔层之间的粘结层；
所述PE膜层由包含以下重量份的原料制成：熔融指数为0.9-1.1g/10min、密度为0.920-0.922g/cm3的LLDPE 40-45份，熔融指数为1.9-2.1g/10min、密度为0.917-0.920g/cm3的m-LLDPE 35-40份以及乙烯-醋酸乙烯酯共聚物15-25份。
通过采用上述技术方案，本申请的电缆绕包层用复合膜包括PE膜层、PET膜层、粘结层以及铝箔层，其对电缆绝缘层具有一定的粘结力，并且还具有很好的拉伸强度以及抗撕裂性能；在对电缆进行加工时，将绝缘层原料通过挤出机挤出包覆在电缆导体的外周，以在导体外形成绝缘层；然后采用复合膜对绝缘层进行缠绕，利用绝缘层加工后表面的余温，可以提高具有自粘作用的复合膜对绝缘层的粘结力，通过绕包工艺，在几根导体的绝缘层外形成绕包层；由于本申请的复合膜的PE膜层具有自粘作用，在绕包的过程中，即使绕包层的紧固度没有达到要求，经过包覆后的几根导体也不容易松散，从而可以降低电缆的次品率，提高工作效率。
由于PE的化学式为化学式为[CH2CH2]n，不含有极性基团，而PET化学式为[COC6H4COOCH2CH2O]n，含有极性基团，二者的相容性相差较大，通过在PE膜的原料中加入含有极性基团的乙烯-醋酸乙烯酯共聚物使其具有较好的热封效果，在PE膜与PET膜复合的时候，通过PE膜的自粘性，还可以提高PE膜与PET膜的粘结强度，从而提高复合膜的稳定性；通过PET膜可以为复合膜提供良好的拉伸强度以及抗撕裂强度，而铝箔作为金属箔导电材料，具有很好的电磁屏蔽效果，由此制得的复合膜不仅具有较好的粘结性能、拉伸强度、抗撕裂强度，而且还具有很好的电磁屏蔽效果。
优选的，所述PE膜的原料还包括3-6重量份的改性蒙脱土，所述改性蒙脱土由蒙脱土经粉碎、预处理剂改性以及氢化松香甘油酯后制得。
通过采用上述技术方案，蒙脱土由于层间的大量无机离子而表现出来的疏油性，不利于其在聚合物基体中的分散，通过预处理剂以及氢化松香甘油酯对蒙脱土进行处理，可以改变蒙脱土表面的高极性，使蒙脱土层间由亲水性转变为亲油性，降低其表面能；在改性蒙脱土与PE混合时，在经过摩擦、剪切的作用下，改性蒙脱土在PE基体中被剥离并呈均匀分散于基体中，一方面可以提高PE膜的拉伸强度以及抗撕裂性能，另一方面改性蒙脱土可以作为一种增粘架桥剂，提高PE膜与绝缘层以及PET膜的粘结强度，从而提高复合膜的稳定性。
优选的，所述预处理剂由重量比为5:3:2的月桂醇聚氧乙烯醚硫酸酯钠盐、十二烷基硫酸钠以及乙烯基三(β-甲氧基乙氧基)硅烷组成。
通过采用上述技术方案，采用由月桂醇聚氧乙烯醚硫酸酯钠盐、十二烷基硫酸钠以及γ-氨丙基三乙氧基硅烷复配的预处理剂对蒙脱土进行处理，可以增加蒙脱土的层间间距，并且利用月桂醇聚氧乙烯醚硫酸酯钠盐、十二烷基硫酸钠以及乙烯基三(β-甲氧基乙氧基)硅烷性能的差异，在蒙脱土膨胀的过程中，可以形成疏松的结构，不仅可以提高蒙脱土的层间间距，有利于氢化松香甘油酯的进入，而且还有利于其在PE基体中的剥离，提高其在PE基体中的分散均匀性。
优选的，所述粘结层由EVA胶膜制成；
所述EVA胶膜由包含以下重量份的原料制成：取乙烯-醋酸乙烯酯共聚物80-90份、m-LLDPE6-8份、聚乙烯醇缩丁醛3-5份、改性蒙脱土2-3份、抗氧剂0.3-0.5份以及润滑剂1-2份；所述熔融指数为1.9-2.1g/10min、密度为0.917-0.920g/cm3的m-LLDPE；
所述改性蒙脱土由蒙脱土经粉碎、预处理剂改性以及氢化松香甘油酯后制得。
通过采用上述技术方案，EVA胶膜以乙烯-醋酸乙烯酯共聚物为主要原料，通过m-LLDPE、聚乙烯醇缩丁醛、改性蒙脱土、抗氧剂以及润滑剂的配合，可以提高EVA胶膜的对PET以及铝箔的粘结力，提高EVA胶膜的拉伸强度，使其适配于PET膜以及铝箔的力学性能，可以防止其发生分层的现象，有利于提高复合膜的稳定性。
优选的，所述PE膜层、PET膜层以及铝箔层的厚度比为3:4:3。
通过采用上述技术方案，PE膜、PET膜以及铝箔的厚度为3:4:3，由此制得的复合膜兼具优异的力学性能以及粘结性能。
第二方面，本申请提供一种电缆绕包层用复合膜的制备方法，采用如下的技术方案：一种电缆绕包层用复合膜的制备方法，包括以下步骤：
S1、将PE膜置于复合机的第一放卷辊上，将PET膜置于复合机的第二放卷辊上，第一放卷辊的温度为70-80℃、张力为30-40N，第二放卷辊的温度为80-90℃、张力为40-45N，使得PE膜覆于PET膜上，复合速度80-100m/min，并通过压膜辊对二者进行加固复合，保持压膜辊的压力为0.2-0.4Mpa；通过复合辊进行收卷，复合辊的温度为40-50℃，压力为0.2-0.4Mpa，收卷张力为30-40N，复合后得到复合薄膜；
S2、将复合薄膜置于复合机的第三放卷辊上，第三放卷辊的温度为70-80℃、张力为30-40N；将EVA胶膜置于复合机的第四放卷辊上，第四放卷辊的温度为60-70℃、张力为10-20N；使EVA胶膜覆于复合薄膜的PET膜的一侧，复合速度80-100m/min，并通过压胶辊对二者进行加固复合，保持压胶辊的压力为0.2-0.4Mpa；然后将预热后的铝箔覆于复合薄膜上，使铝箔与EVA胶膜接触，在温度为120-130℃、压力为3-5Mpa的条件下热压复合30-40s后，使复合薄膜覆于铝箔上，得到复合膜。
通过采用上述技术方案，通过复合机在一定的温度以及压力下，将PE膜以及PET膜复合后，得到复合薄膜，而后将复合薄膜与铝箔通过EVA胶膜进行粘结，以得到复合膜，其制备的产品的性能稳定，对电缆绝缘材料具有很好的缠绕效果。
优选的，所述PE膜采用如下方法制备：将LLDPE、m-LLDPE以及乙烯-醋酸乙烯酯共聚物高速混合后，得到混合料；将混合料置于吹膜机中，在160-190℃的温度下熔融、挤出、吹膜后，制得PE膜。
通过采用上述技术方案，将PE膜的原料通过熔融、吹膜制得，其制备方法简单，易于实现。
优选的，所述PE膜的原料还包括3-6重量份的改性蒙脱土，所述改性蒙脱土采用如下方法制备而成：
①取蒙脱土，将其研磨过筛后，得到蒙脱土粉；以重量份数计，向10份蒙脱土粉中加入0.05-0.2份的分散剂以及100份水，搅拌均匀，得到蒙脱土悬浊液；
②向蒙脱土悬浊液中加入0.2-0.4份的预处理剂，以2000-3000r/min的速度，搅拌10-20min后，使其在80-100℃的温度下，干燥36-48h，然后将其粉碎过筛后，得到预处理蒙脱土；
③向预处理蒙脱土中加入2-4份、10wt％的氢化松香甘油酯的丙酮溶液，在30-40℃的温度下，以200-400r/min的速度搅拌1h，再保温静置3-5h，然后升温至85-90℃，除去丙酮溶剂，得到固化物；将固化物粉碎过筛后，得到改性蒙脱土。
通过采用上述技术方案，在本申请中，先将蒙脱土粉碎后可以使其细化，有利于提高后续工艺的效率，由于蒙脱土细化后容易发生团聚现象，因此将其在分散剂的作用下，使得在水中具有较好的分散性，有利于提高体系的稳定性；将分散后的蒙脱土在预处理剂的作用下，可以增加蒙脱土的体积，使得晶层间距增加，有利于氢化松香甘油酯的进入以及蒙脱土片层的剥离；将氢化松香甘油酯的丙酮溶液加入后，使得氢化松香甘油酯进入到蒙脱土的层间以及包覆在其表面，以此得到改性蒙脱土。将改性蒙脱土加入PE膜的原料中，在经过摩擦、剪切的作用下，改性蒙脱土在PE基体中被剥离并呈均匀分散于基体中，一方面可以提高PE膜的拉伸强度以及抗撕裂性能，另一方面改性蒙脱土可以作为一种增粘架桥剂，提高PE膜与绝缘层以及PET膜的粘结强度，从而提高复合膜的稳定性。
优选的，所述分散剂为六偏磷酸钠、聚羧酸钠盐分散剂中的一种。
通过采用上述技术方案，六偏磷酸钠、聚羧酸钠盐分散剂可以提高蒙脱土在水中的悬浮分散性，有利于后续工艺的进行。
优选的，所述EVA胶膜采用如下方法制备：以重量份数计，取乙烯-醋酸乙烯酯共聚物80-90份、m-LLDPE 6-8份、聚乙烯醇缩丁醛3-5份、改性蒙脱土2-3份、抗氧剂0.3-0.5份以及润滑剂1-2份，将其预混后，得到预混料；将预混料在140-180℃的温度下熔融挤出后，将熔体流延成膜后，得到EVA胶膜。
通过采用上述技术方案，将EVA胶膜的原料经过熔融挤出、流延成膜后，其制备方法简单，易于操作；并且在PET膜与铝箔复合的过程中，采用EVA胶膜相较于溶性型胶水，其使用更加方便，并且有利于提高PET膜与铝箔复合后的平整性，提高复合膜的外观质量。
综上所述，本申请具有以下有益效果：
1、由于本申请采用具有自粘性能的PE膜与PET膜、铝箔膜复合，由此制得的复合膜不仅具有较好的粘结性能、拉伸强度、抗撕裂强度，而且还具有很好的电磁屏蔽效果，在对电缆导体进行绕包时，包覆后的导体不易松散，具有很好的包覆效果。
2、本申请中的PE膜的原料中还添加了改性蒙脱土，通过改性蒙脱土的加入，不仅可以提高PE膜的拉伸强度、抗撕裂强度等力学性能，而且还可以提高其对PET膜、铝箔以及PVC绝缘层的粘结力，从而可以提高复合膜的包覆缠绕效果。
3、本申请的EVA胶膜用于将PET膜以及铝箔进行粘结，可以防止复合膜发生分层的现象，有利于提高复合膜的稳定性。
附图说明
图1是本申请背景技术附图中的电缆的剖面示意图；
图2是本申请实施例1的绕包层的层结构剖面示意图。
图中，1、导体；2、耐火层；3、绝缘层；4、填充层；5、绕包层；51、PE膜层；52、PET膜层；53、铝箔层；54、粘结层；6、保护套层。
具体实施方式
以下结合附图以及实施例对本申请作进一步详细说明。
改性蒙脱土的制备例以下制备例中的预处理剂由重量比为5:3:2的月桂醇聚氧乙烯醚硫酸酯钠盐、十二烷基硫酸钠以及乙烯基三(β-甲氧基乙氧基)硅烷组成；月桂醇聚氧乙烯醚硫酸酯钠盐CAS号为9004-82-4，选自南通润丰石油化工有限公司提供的型号为C24E2S的脂肪醇聚氧乙烯醚硫酸钠AES；十二烷基硫酸钠选自上海白猫股份有限公司提供的K12十二烷基硫酸钠；乙烯基三(β-甲氧基乙氧基)硅烷选自杭州赛特高分子科技有限公司提供的A-172硅烷偶联剂；聚羧酸钠盐分散剂选自东莞博高化工有限公司提供的型号为BG554的聚羧酸钠盐分散剂；氢化松香甘油酯选自武汉卡布达化工有限公司提供的氢化松香甘油酯。
改性蒙脱土的制备例1：
①取蒙脱土，将其研磨过200目筛后，得到蒙脱土粉；以重量分数计，向10kg蒙脱土粉中加入0.05kg的六偏磷酸钠以及100kg水，以1000r/min的速度，搅拌20min，得到蒙脱土悬浊液；
②向蒙脱土悬浊液中加入0.2kg的预处理剂(由0.1kg月桂醇聚氧乙烯醚硫酸酯钠盐、0.06kg十二烷基硫酸钠以及0.04kg乙烯基三(β-甲氧基乙氧基)硅烷组成)，以2000r/min的速度，搅拌10min后，使其在80℃的温度下，干燥36h，然后将其粉碎过200目筛后，得到预处理蒙脱土；
③向预处理蒙脱土中加入2kg、10wt％的氢化松香甘油酯的丙酮溶液，在30℃的温度下，以200r/min的速度搅拌1h，再保温静置3h，然后升温至85℃，蒸去丙酮溶剂，得到固化物；将固化物粉碎过200目筛后，得到改性蒙脱土。
改性蒙脱土的制备例2：
①取蒙脱土，将其研磨过200目筛后，得到蒙脱土粉；以重量分数计，向10kg蒙脱土粉中加入0.1kg的聚羧酸钠盐分散剂以及100kg水，以1000r/min的速度，搅拌20min，得到蒙脱土悬浊液；
②向蒙脱土悬浊液中加入0.3kg的预处理剂(由0.15kg月桂醇聚氧乙烯醚硫酸酯钠盐、0.09kg十二烷基硫酸钠以及0.06kg乙烯基三(β-甲氧基乙氧基)硅烷组成)，以2500r/min的速度，搅拌15min后，使其在90℃的温度下，干燥42h，然后将其粉碎过200目筛后，得到预处理蒙脱土；
③向预处理蒙脱土中加入3kg、10wt％的氢化松香甘油酯的丙酮溶液，在35℃的温度下，以300r/min的速度搅拌1h，再保温静置4h，然后升温至87℃，蒸去丙酮溶剂，得到固化物；将固化物粉碎过200目筛后，得到改性蒙脱土。
改性蒙脱土的制备例3：
①取蒙脱土，将其研磨过200目筛后，得到蒙脱土粉；以重量分数计，向10kg蒙脱土粉中加入0.2kg的六偏磷酸钠以及100kg水，以1000r/min的速度，搅拌20min，得到蒙脱土悬浊液；
②向蒙脱土悬浊液中加入0.4kg的预处理剂(由0.2kg月桂醇聚氧乙烯醚硫酸酯钠盐、0.12kg十二烷基硫酸钠以及0.08kg乙烯基三(β-甲氧基乙氧基)硅烷组成)，以3000r/min的速度，搅拌20min后，使其在100℃的温度下，干燥48h，然后将其粉碎过200目筛后，得到预处理蒙脱土；
③向预处理蒙脱土中加入4kg、10wt％的氢化松香甘油酯的丙酮溶液，在40℃的温度下，以400r/min的速度搅拌1h，再保温静置5h，然后升温至90℃，蒸去丙酮溶剂，得到固化物；将固化物粉碎过200目筛后，得到改性蒙脱土。
PE膜的制备例以下制备例中的LLDPE选自美国埃克森美孚提供的牌号为MJA-042的LLDPE，其熔融指数为1g/10min，密度为0.921g/cm3，其具有拉伸强度高、韧性好，无爽滑剂和抗粘连剂的特点；m-LLDPE选自美国埃克森美孚提供的牌号为2018MB的m-LLDPE，其熔融指数为2g/10min，密度为0.918g/cm3，其具有热熔性好、软化点低、加工性能好、柔韧性好以及电绝缘性能优异的特点；乙烯-醋酸乙烯酯共聚物选自韩国乐天提供的牌号为VA930的乙烯-醋酸乙烯酯共聚物，其密度为0.95g/cm3，VA含量为28％。
PE膜的制备例1：将40kg LLDPE、35kg m-LLDPE以及25kg乙烯-醋酸乙烯酯共聚物在1000r/min的速度高速混合15min后，得到混合料；将混合料置于吹膜机中，设置吹膜机各区的温度为一区160℃、二区170℃、三区180℃、四区190℃、五区180℃，模头温度为180℃，经过熔融、挤出后，以30r/min的速度牵引薄膜，将薄膜分切收卷后，制得厚度为10μm的PE膜。
PE膜的制备例2：将42.5kg LLDPE、37.5kg m-LLDPE以及20kg乙烯-醋酸乙烯酯共聚物在1000r/min的速度高速混合15min后，得到混合料；将混合料置于吹膜机中，设置吹膜机各区的温度为一区160℃、二区170℃、三区180℃、四区190℃、五区180℃，模头温度为180℃，经过熔融、挤出后，以30r/min的速度牵引薄膜，将薄膜分切收卷后，制得厚度为10μm的PE膜。
PE膜的制备例3：将45kg LLDPE、40kg m-LLDPE以及15kg乙烯-醋酸乙烯酯共聚物在1000r/min的速度高速混合15min后，得到混合料；将混合料置于吹膜机中，设置吹膜机各区的温度为一区160℃、二区170℃、三区180℃、四区190℃、五区180℃，模头温度为180℃，经过熔融、挤出后，以30r/min的速度牵引薄膜，将薄膜分切收卷后，制得厚度为10μm的PE膜。
PE膜的制备例4：本制备例与PE膜的制备例1的不同之处在于，将3kg的改性蒙脱土(选自改性蒙脱土的制备例1)加入，与40kg LLDPE、35kg m-LLDPE以及25kg乙烯-醋酸乙烯酯共聚物在1000r/min的速度高速混合15min后，得到混合料。
PE膜的制备例5：本制备例与PE膜的制备例1的不同之处在于，将4.5kg的改性蒙脱土(选自改性蒙脱土的制备例2)加入，与40kg LLDPE、35kg m-LLDPE以及25kg乙烯-醋酸乙烯酯共聚物在1000r/min的速度高速混合15min后，得到混合料。
PE膜的制备例6：本制备例与PE膜的制备例1的不同之处在于，将6kg的改性蒙脱土(选自改性蒙脱土的制备例3)加入，与40kg LLDPE、35kg m-LLDPE以及25kg乙烯-醋酸乙烯酯共聚物在1000r/min的速度高速混合15min后，得到混合料。
PE膜的制备例7：本制备例与PE膜的制备例1的不同之处在于，原料中未添加乙烯-醋酸乙烯酯共聚物。
EVA胶膜的制备例
以下制备例中的乙烯-醋酸乙烯酯共聚物选自美国阿科玛提供的牌号为EVA42-60的乙烯-醋酸乙烯酯共聚物，其VA含量为42％；m-LLDPE选自美国埃克森美孚提供的牌号为2018MB的m-LLDPE，其熔融指数为2g/10min，密度为0.918g/cm3，改性蒙脱土选自改性蒙脱土的制备例1制备而成。
EVA胶膜的制备例1：取乙烯-醋酸乙烯酯共聚物80kg、m-LLDPE 6kg、聚乙烯醇缩丁醛3kg、改性蒙脱土2kg、抗氧剂1010 0.5kg、聚乙烯蜡1kg，将其以1000r/min的速度混合10min，得到预混料；将预混料置于双螺杆挤出机中，设置双螺杆挤出机的一区140℃、二区150℃、三区170℃、四区180℃、五区180℃，模头温度为170℃，螺杆转速为50r/min，经过熔融、挤出后，将熔体通过流延机流延成膜，流延温度为180℃，经过收卷、冷却后，得到厚度为3μm的EVA胶膜。
EVA胶膜的制备例2：取乙烯-醋酸乙烯酯共聚物85kg、m-LLDPE 7kg、聚乙烯醇缩丁醛4kg、改性蒙脱土2.5kg、抗氧剂1010 0.4kg以及润滑剂1.5kg，将其以1000r/min的速度混合10min，得到预混料；将预混料置于双螺杆挤出机中，设置双螺杆挤出机的一区140℃、二区150℃、三区170℃、四区180℃、五区180℃，模头温度为170℃，螺杆转速为50r/min，经过熔融、挤出后，将熔体通过流延机流延成膜，流延温度为180℃，经过收卷、冷却后，得到厚度为3μm的EVA胶膜。
EVA胶膜的制备例3：取乙烯-醋酸乙烯酯共聚物90kg、m-LLDPE 8kg、聚乙烯醇缩丁醛5kg、改性蒙脱土3kg、抗氧剂1010 0.5kg以及聚乙烯蜡2kg，将其以1000r/min的速度混合10min，得到预混料；将预混料置于双螺杆挤出机中，设置双螺杆挤出机的一区140℃、二区150℃、三区170℃、四区180℃、五区180℃，模头温度为170℃，螺杆转速为50r/min，经过熔融、挤出后，将熔体通过流延机流延成膜，流延温度为180℃，经过收卷、冷却后，得到厚度为3μm的EVA胶膜。
EVA胶膜的制备例4：本制备例与EVA胶膜的制备例1的不同之处在于，原料中未添加改性蒙脱土。
EVA胶膜的制备例5：本制备例与EVA胶膜的制备例1的不同之处在于，原料中未添加m-LLDPE以及聚乙醇缩丁醛。
实施例
实施例1：一种电缆绕包层用复合膜，参见图1和图2，包括与电缆绝缘层3接触的PE膜层51、复合于PE膜层51上的PET膜层52、复合于PET膜层52上的铝箔层53以及设于PET膜层52与铝箔层53之间的粘结层54。
一种电缆绕包层用复合膜采用如下方法制备而成：
S1、将PE膜(选自PE膜的制备例1)置于复合机的第一放卷辊上，将PET膜置于复合机的第二放卷辊上，第一放卷辊的温度为70℃、张力为30N，第二放卷辊的温度为80℃、张力为40N，使得PE膜覆于PET膜上，复合速度80m/min，并通过压膜辊对二者进行加固复合，保持压膜辊的压力为0.2Mpa；通过复合辊进行收卷，复合辊的温度为40℃，压力为0.2Mpa，收卷张力为30N，复合后得到复合薄膜；
S2、将复合薄膜置于复合机的第三放卷辊上，第三放卷辊的温度为70℃、张力为30N；将EVA胶膜(选自EVA胶膜的制备例1)置于复合机的第四放卷辊上，第四放卷辊的温度为60℃、张力为10N；使EVA胶膜覆于复合薄膜的PET膜的一侧，复合速度80m/min，并通过压胶辊对二者进行加固复合，保持压胶辊的压力为0.2Mpa；然后将预热后的铝箔覆于复合薄膜上，使铝箔与EVA胶膜接触，在温度为120℃、压力为3Mpa的条件下热压复合30s后，使复合薄膜覆于铝箔上，得到PE膜层、PET膜层以及铝箔层的厚度比为3:4:3的复合膜。
实施例2与实施例1的不同之处在于一种电缆绕包层用复合膜采用如下方法制备而成：
S1、将PE膜(选自PE膜的制备例2)置于复合机的第一放卷辊上，将PET膜置于复合机的第二放卷辊上，第一放卷辊的温度为75℃、张力为35N，第二放卷辊的温度为85℃、张力为42N，使得PE膜覆于PET膜上，复合速度90m/min，并通过压膜辊对二者进行加固复合，保持压膜辊的压力为0.3Mpa；通过复合辊进行收卷，复合辊的温度为45℃，压力为0.3Mpa，收卷张力为35N，复合后得到复合薄膜；
S2、将复合薄膜置于复合机的第三放卷辊上，第三放卷辊的温度为75℃、张力为35N；将EVA胶膜(选自EVA胶膜的制备例2)置于复合机的第四放卷辊上，第四放卷辊的温度为65℃、张力为15N；使EVA胶膜覆于复合薄膜的PET膜的一侧，复合速度90m/min，并通过压胶辊对二者进行加固复合，保持压胶辊的压力为0.3Mpa；然后将预热后的铝箔覆于复合薄膜上，使铝箔与EVA胶膜接触，在温度为125℃、压力为4Mpa的条件下热压复合35s后，使复合薄膜覆于铝箔上，得到PE膜层、PET膜层以及铝箔层的厚度比为3:4:3的复合膜。
实施例3与实施例1的不同之处在于一种电缆绕包层用复合膜采用如下方法制备而成：
S1、将PE膜(选自PE膜的制备例3)置于复合机的第一放卷辊上，将PET膜置于复合机的第二放卷辊上，第一放卷辊的温度为80℃、张力为40N，第二放卷辊的温度为90℃、张力为45N，使得PE膜覆于PET膜上，复合速度100m/min，并通过压膜辊对二者进行加固复合，保持压膜辊的压力为0.4Mpa；通过复合辊进行收卷，复合辊的温度为50℃，压力为0.4Mpa，收卷张力为40N，复合后得到复合薄膜；
S2、将复合薄膜置于复合机的第三放卷辊上，第三放卷辊的温度为80℃、张力为40N；将EVA胶膜(选自EVA胶膜的制备例3)置于复合机的第四放卷辊上，第四放卷辊的温度为70℃、张力为20N；使EVA胶膜覆于复合薄膜的PET膜的一侧，复合速度100m/min，并通过压胶辊对二者进行加固复合，保持压胶辊的压力为0.4Mpa；然后将预热后的铝箔覆于复合薄膜上，使铝箔与EVA胶膜接触，在温度为130℃、压力为5Mpa的条件下热压复合40s后，使复合薄膜覆于铝箔上，得到PE膜层、PET膜层以及铝箔层的厚度比为3:4:3的复合膜。
实施例4：本实施例与实施例1的不同之处在于，PE膜选自PE膜的制备例4制备而成。
实施例5：本实施例与实施例1的不同之处在于，PE膜选自PE膜的制备例5制备而成。
实施例6：本实施例与实施例1的不同之处在于，PE膜选自PE膜的制备例6制备而成。
对比例
对比例1：本对比例与实施例1的不同之处在于，PE膜选自PE膜的制备例7制备而得，该PE膜的制备原料中未添加乙烯-醋酸乙烯酯共聚物。
对比例2：本对比例与实施例1的不同之处在于，EVA胶膜选自EVA胶膜的制备例4制备而得。
对比例3：本对比例与实施例1的不同之处在于，EVA胶膜选自EVA胶膜的制备例5制备而得。
性能测试
按照如下方法，对实施例1-6以及对比例1-3制备的复合膜的性能进行测试，将测试结果示于表1。
拉伸性能以及断裂伸长率：根据GB/T13022-1991《塑料薄膜拉伸性能测试方法》测试。
撕裂强度：根据GB/T16578.1-2008《塑料薄膜和薄片耐撕裂性能的测定第1部分：裤形撕裂法》。
剥离强度：为了验证复合膜的各层之间的粘结力，裁制100×50mm的复合膜样品，将复合膜置于温度为(23±2)℃、相对湿度为(50±5)％的环境下存放40h，分别PE膜与PET膜、PET膜与铝箔预先剥开30mm，然后将试样放置在拉力试验机中，按照100mm/min的剥离速度对试样进行剥离，将分别测试PE膜与PET膜、PET膜与铝箔的剥离强度。
由于绕包层材料是通过缠绕的方式对导体进行包覆，复合膜的PE膜除了与电缆的绝缘层接触外，在其缠绕的过程中，PE膜还会与铝箔进行搭接，因此，需要对PE膜与绝缘层(PVC材料)的剥离强度，以及PE膜与铝箔的剥离强度进行测试。
PE膜与PVC之间的剥离强度采用如下方法测试：裁制120×50mm的复合膜样品以及100×50×10mmPVC板材，将复合膜与PVC板材置于温度为(23±2)℃、相对湿度为(50±5)％的环境下存放40h，然后将PVC板材加热至60℃后，立即将复合膜样品的PE膜的一侧贴合于PVC板材上，使得复合膜与PVC板材在宽度方向完全重合，然后在复合膜与PVC重合的部位施加830Pa的静压力，持续30min，得到复合膜/PVC试样，然后将试样放置在拉力试验机中，按照100mm/min的剥离速度对试样进行剥离，测试复合膜与PVC之间的剥离强度。
PE膜与铝箔之间的剥离强度采用如下方法测试：裁制100×50mm的复合膜样品，将复合膜置于温度为(23±2)℃、相对湿度为(50±5)％的环境下存放40h；然后将两个复合膜样品进行搭接，使二者在宽度方向完全重合，并且一个复合膜的PE膜层搭接在另一个复合膜的铝箔层上，在长度方向的搭接部分长度为30mm，搭接试样总长度为170mm，然后对搭接部位施加830Pa的静压力，持续30min，得到复合膜/复合膜搭接试样，然后将试样放置在拉力试验机中，按照100mm/min的剥离速度对试样进行剥离，测试PE膜与铝箔之间的剥离强度。
表1实施例1-6以及对比例1-3复合膜性能测试表
Figure BDA0002679087300000111
结合实施例1和对比例1并结合表1可以看出，实施例1中复合膜的拉伸强度、撕裂强度以及PE膜/PET膜、PE膜/PVC板材、PE膜/铝箔的剥离强度明显优于对比例1中的复合膜的拉伸强度、撕裂强度以及剥离强度，说明当PE膜中乙烯-醋酸乙烯酯共聚物的加入可以明显提高PE膜的自粘性，从而提高PE膜与PET膜、PVC以及铝箔之间的粘结强度。
结合实施例1、实施例4并结合表1可以看出，实施例4中复合膜的拉伸强度、撕裂强度以及PE膜/PET膜、PE膜/PVC板材、PE膜/铝箔的剥离强度明显优于对比例1中的复合膜的拉伸强度、撕裂强度以及剥离强度，说明当PE膜中改性蒙脱土的加入可以明显提高PE膜的自粘性，从而提高PE膜与PET膜、PVC以及铝箔之间的粘结强度。
结合实施例1、对比例2、对比例3并结合表1可以看出，对比例2以及对比例3中的PET膜/铝箔的剥离强度明显低于实施例1的PET膜/铝箔的剥离强度，说明EVA胶膜的原料改性蒙脱土、m-LLDPE以及聚乙烯醇缩丁醛的加入可以明显提高EVA胶膜与铝箔、PET膜的粘结强度。
本具体实施例仅仅是对本申请的解释，其并不是对本申请的限制，本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改，但只要在本申请的权利要求范围内都受到专利法的保护。

Claims (10)

1.一种电缆绕包层用复合膜，其特征在于，包括与电缆绝缘层接触的PE膜层、复合于PE膜层上的PET膜层、复合于PET膜层上的铝箔层以及设于PET膜层与铝箔层之间的粘结层；
所述PE膜层由包含以下重量份的原料制成：熔融指数为0.9-1.1g/10min、密度为0.920-0.922g/cm3的LLDPE 40-45份，熔融指数为1.9-2.1g/10min、密度为0.917-0.920g/cm3的m-LLDPE 35-40份以及乙烯-醋酸乙烯酯共聚物15-25份。
2.根据权利要求1所述的一种电缆绕包层用复合膜，其特征在于，所述PE膜的原料还包括3-6重量份的改性蒙脱土，所述改性蒙脱土由蒙脱土经粉碎、预处理剂改性以及氢化松香甘油酯后制得。
3.根据权利要求2所述的一种电缆绕包层用复合膜，其特征在于，所述预处理剂由重量比为5:3:2的月桂醇聚氧乙烯醚硫酸酯钠盐、十二烷基硫酸钠以及乙烯基三（β-甲氧基乙氧基）硅烷组成。
4.根据权利要求1所述的一种电缆绕包层用复合膜，其特征在于，所述粘结层由EVA胶膜制成；
所述EVA胶膜由包含以下重量份的原料制成：取乙烯-醋酸乙烯酯共聚物80-90份、m-LLDPE 6-8份、聚乙烯醇缩丁醛3-5份、改性蒙脱土2-3份、抗氧剂0.3-0.5份以及润滑剂1-2份；
所述熔融指数为1.9-2.1g/10min、密度为0.917-0.920g/cm3的m-LLDPE；
所述改性蒙脱土由蒙脱土经粉碎、预处理剂改性以及氢化松香甘油酯后制得。
5.根据权利要求1所述的一种电缆绕包层用复合膜，其特征在于，所述PE膜层、PET膜层以及铝箔层的厚度比为3:4:3。
6.一种如权利要求1所述的电缆绕包层用复合膜的制备方法，其特征在于，包括以下步骤：
S1、将PE膜置于复合机的第一放卷辊上，将PET膜置于复合机的第二放卷辊上，第一放卷辊的温度为70-80℃、张力为30-40N，第二放卷辊的温度为80-90℃、张力为40-45N，使得PE膜覆于PET膜上，复合速度80-100m/min，并通过压膜辊对二者进行加固复合，保持压膜辊的压力为0.2-0.4Mpa；通过复合辊进行收卷，复合辊的温度为40-50℃，压力为0.2-0.4Mpa，收卷张力为30-40N，复合后得到复合薄膜；
S2、将复合薄膜置于复合机的第三放卷辊上，第三放卷辊的温度为70-80℃、张力为30-40N；将EVA胶膜置于复合机的第四放卷辊上，第四放卷辊的温度为60-70℃、张力为10-20N；使EVA胶膜覆于复合薄膜的PET膜的一侧，复合速度80-100m/min，并通过压胶辊对二者进行加固复合，保持压胶辊的压力为0.2-0.4Mpa；然后将预热后的铝箔覆于复合薄膜上，使铝箔与EVA胶膜接触，在温度为120-130℃、压力为3-5Mpa的条件下热压复合30-40s后，使复合薄膜覆于铝箔上，得到复合膜。
7.根据权利要求6所述的电缆绕包层用复合膜的制备方法，其特征在于，所述PE膜采用如下方法制备：将LLDPE、m-LLDPE以及乙烯-醋酸乙烯酯共聚物高速混合后，得到混合料；将混合料置于吹膜机中，在160-190℃的温度下熔融、挤出、吹膜后，制得PE膜。
8.根据权利要求6所述的电缆绕包层用复合膜的制备方法，其特征在于，所述PE膜的原料还包括3-6重量份的改性蒙脱土，所述改性蒙脱土采用如下方法制备而成：
①取蒙脱土，将其研磨过筛后，得到蒙脱土粉；以重量份数计，向10份蒙脱土粉中加入0.05-0.2份的分散剂以及100份水，搅拌均匀，得到蒙脱土悬浊液；
②向蒙脱土悬浊液中加入0.2-0.4份的预处理剂，以2000-3000r/min的速度，搅拌10-20min后，使其在80-100℃的温度下，干燥36-48h，然后将其粉碎过筛后，得到预处理蒙脱土；
③向预处理蒙脱土中加入2-4份、10wt%的氢化松香甘油酯的丙酮溶液，在30-40℃的温度下，以200-400r/min的速度搅拌1h，再保温静置3-5h，然后升温至85-90℃，除去丙酮溶剂，得到固化物；将固化物粉碎过筛后，得到改性蒙脱土。
9.根据权利要求8所述的电缆绕包层用复合膜的制备方法，其特征在于，所述分散剂为六偏磷酸钠、聚羧酸钠盐分散剂中的一种。
10.根据权利要求6所述的电缆绕包层用复合膜的制备方法，其特征在于，所述EVA胶膜采用如下方法制备：以重量份数计，取乙烯-醋酸乙烯酯共聚物80-90份、m-LLDPE 6-8份、聚乙烯醇缩丁醛3-5份、改性蒙脱土2-3份、抗氧剂0.3-0.5份以及润滑剂1-2份，将其预混后，得到预混料；将预混料在140-180℃的温度下熔融挤出后，将熔体流延成膜后，得到EVA胶膜。
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