CN1123582A - 聚合物组合物及电线绝缘 - Google Patents

聚合物组合物及电线绝缘 Download PDF

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CN1123582A
CN1123582A CN94192146A CN94192146A CN1123582A CN 1123582 A CN1123582 A CN 1123582A CN 94192146 A CN94192146 A CN 94192146A CN 94192146 A CN94192146 A CN 94192146A CN 1123582 A CN1123582 A CN 1123582A
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D·J·德斯敦
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Abstract

用于电线绝缘的聚合物共混物包含固有极限氧指数(L.O.I)不高于21％的第一聚合物(聚酯)和至多40％重量的聚酰亚胺-硅氧烷(PIS)共聚物。优选的聚酯是聚对苯二甲酸丁二醇酯或聚酯-酯嵌段共聚物。优选的电线结构是在聚乙烯或聚酯的芯绝缘层上覆盖有聚酯/PIS共聚物的共混物的外层。

Description

聚合物组合物及电线绝缘
本发明涉及含有聚酰亚胺硅氧烷，尤其是聚醚酰亚胺硅氧烷的绝缘聚合物组合物，并涉及带有一层由所说的组合物形成的绝缘或外层材料的电线或电缆。
含有聚醚酰亚胺硅氧烷的聚合物组合物可从许多专利申请得知。例如，EP-A-0407061叙述了具有不含卤素塑料材料的内包覆层和不含卤素的硅氧烷与聚醚酰亚胺的共聚物或其混合物的硬质柔性的外包覆层的电线。已经知道与聚醚酰亚胺有关的外包覆层具有有利的低可燃性，尽管更好的是再增加一层聚醚酮醚的外层以便进一步降低可燃性，并提高耐切割性和耐磨性以及耐液体或气体化学品的浸蚀。EP-A-0407061还叙述了将未加规定数量的聚亚苯基醚或尼龙与聚醚酰亚胺硅氧烷进行共混的方法。
在另一篇文献，即EP-030760中，通过将阻燃的聚醚酰亚胺硅氧烷聚醚酰亚胺共聚物的共混物与氟碳聚合物进行共混而达到改善可燃性。所述的组合物特别适用于飞机仪表板和内部材料。尽管这种材料具有很好的阻燃性，但是它们确实具有含有卤素的缺点，这是不希望的，而且实际上对于某些应用，常常被法律禁止，因为如果在火灾时，会释放出有毒性的卤素。
EP-A-0323142叙述了用于电线绝缘的三元聚合物共混物，它含有聚亚芳基酮醚与聚醚酰亚胺和硅氧烷聚酰亚胺共聚物的共混物。这些聚合物的每一组分均具有优异的阻燃性能，因而其三元共混物同样具有优异的阻燃性能。然而不利的是所有的组分均是昂贵的，因此，三元共混物同样也是昂贵的。
聚合物组合物的阻燃性能可以通过分析聚合物的极限氧指数(L.O.I.)而容易地进行评定。该测定按ASTM D2863-1987规范进行。它测定的是使被测试的聚合物燃烧所需氧气的最低百分数。因此，较高数值的L.O.I.表明材料具有较好的阻燃性能。具体说，具有至少21％L.O.I.的聚合物组合物在空气中将不会燃烧，因而对于某些应用来说是优选的。本发明中提及的L.O.I.是按照ASTM D2863-1987测定的。
我们已经发现单独使用时其L.O.I.低于21％的聚合物组合物或聚合物组合物的共混物与少量比例(至多40％重量)的聚酰亚胺-硅氧烷共聚物，更好是聚醚酰亚胺-硅氧烷共聚物进行共混或混合可以显著提高所说聚合物的组合物或共混物的阻燃性。
因此，本发明的首要方面是提供一种L.O.I.至少为27％.，较好至少为28％，更好至少为29％的聚合物组合物，它含下面的共混物：
(a)第一组分，它是一种聚合物或聚合物的共混物，该聚合物或共混物
    (I)在没有其它组分存在时其L.O.I.至多为21％，而且
    (II)基本上不含卤素；和
(b)至多40％重量(以组合物总重量计)的第二组分，它是聚酰亚胺-硅氧烷聚合物，较好是聚醚酰亚胺-硅氧烷聚合物。
组合物的组分以重量百分比来定量表示，并且以组合物总重量为基准。较好是该组合物含有至多35％，更好是至多30％所说的第二组分，甚至可以只含该组分的至多25％或20％。
当我们说一种聚合物或共混物基本上不含卤素时，我们指的是在这种聚合物或共混物中卤素的重量百分数低于0.1％，更好是低于0.01％，最好是低于0.001％。
更好地，第一组分也是不含磷的和/或更好地也是不含硫的。这对于电线和电缆的绝缘性能是非常有利的。对于第一组分，特别优选的材料是聚酯或聚酯的共混物。可以提及的实例是聚醚酯(例如可从杜邦公司得到的Hytrel-5556)，聚酯酯(例如可从Elastogran公司得到的Elastotec E-7011)，聚对苯二甲酸丁二醇酯(例如可从通用电器公司得到的Valox-325)和聚对苯二甲酸丁二醇酯与聚酯酯的共混物。
特别要优先使用聚酯作为第一组分，因为与单独使用聚酰亚胺-硅氧烷(例如聚醚酰亚胺-硅氧烷)相比，聚酯的优点是具有显著提高的耐液体性，例如对烃类液体，特别是对氯代烃类液体，而且也比聚酰亚胺-硅氧烷(例如聚醚酰亚胺-硅氧烷)便宜得多。在没有其它组分存在时，聚酯一般具有约20％的L.O.I.，而令人惊奇的是以聚酯为主要组分的共混物可以获得增强的耐化学性，同时还具有好的阻燃性。
例如，用聚酯作为按照本发明的组合物的主要组分赋予了对于氯代烃类液体，例如1，1，1-三氯乙烷良好的耐液体性。
对于精通此项技术的人来说，组合物中低可燃性的第一组分可以与聚酰亚胺硅氧烷进行有效地混合，这一点并不是显而已见的，而添加至多40％的聚酰亚胺硅氧烷会使整个组合物的L.O.I.增加到至少27，28或29％也不是显而已见的。例如，所用的聚合物各组分之间可以互不相容，而且例如对于精通此项技术的人来说，也没有迹象表明聚酯与聚酰亚胺硅氧烷可以在能使整个组合物获得所希望的阻燃性所要求的聚酰亚胺硅氧烷的浓度下进行共混。鉴于基本上纯的聚酰亚胺硅氧烷(例如聚醚酰亚胺硅氧烷典型地在约300℃进行加工)和聚酯(典型地在约250℃进行加工)具有不同的加工温度，所达到的共混程度尤其令人惊奇。
我们还令人惊奇地发现由聚醚酰亚胺硅氧烷和聚酯共混的组合物的L.O.I.随着与聚酯共混的聚醚酰亚胺硅氧烷浓度由0％增加到100％聚醚酰亚胺硅氧烷(特别是在0％～40％范围)而基本上均匀地增加，即L.O.I.对聚醚酰亚胺浓度的曲线图形基本上是直线，从约20％(100％聚酯/0％聚醚酰亚胺-硅氧烷)上升到46％(100％聚醚酰亚胺-硅氧烷/0％聚酯)。令人惊奇的是聚酯的L.O.I.随着聚醚酰亚胺硅氧烷的加人而增加竟会如此之大，因为对于具有不同初始L.O.I.值的聚合物的共混物(其中低L.O.I.值的材料为主要组分)来说，这种情况并不多见。
除了阻燃性，常常希望聚合物组合物具有良好的(也就是低的)烟雾释放性能。众所周知，当氢氧化镁混合在聚合物组合物中时可以起抑制烟雾的作用。然而氢氧化镁不容易混合在未共混的聚酰亚胺硅氧烷中(尤其在未共混的聚醚酰亚胺硅氧烷中)或其中聚酰亚胺硅氧烷(尤其聚醚酰亚胺硅氧烷)是主要组分的共混物中，因为聚酰亚胺硅氧烷的加工温度一般来说太高。例如聚醚酰亚胺硅氧烷的加工温度是约300℃，在此温度下氢氧化镁是不稳定的。按照本发明，第一组分的加工温度较好最高为270℃，更好是最高为260℃，最好是最高为250℃，而组合物较好是包含有氢氧化镁。氢氧化镁的重量百分比(以组合物总重量计)较好为10～50％，更好为15～40％，最好为20％～30％或约20％。同样，按照本发明，整个组合物的加工温度较好地最高为270℃，更好地最高为260℃，最好地最高为250℃。即使聚酰亚胺硅氧烷是组合物的组分之一，且如果单独使用时，其需要在较高的温度(例如对于聚醚酰亚胺硅氧烷为300℃)下加工，而事实上它仅仅用作为次要组分(其量小于整个组合物重量的40％)，这意味着整个组合物可以在较低的温度下加工。加入了氢氧化镁之后就可以得到具有良好阻燃性能和良好烟雾释放性能的组合物。
按照本发明，所用的特别优选的聚酰亚胺硅氧烷共聚物是聚醚酰亚胺硅氧烷，Siltem 1500(可从通用电器塑料公司购得)。
按照本发明的聚合物组合物较好地是电绝缘的。
本发明的组合物特别适用于电线或电缆的绝缘层，因此本发明的第二个方面是提供带有按照本发明第一方面的聚合物组合物绝缘层的电线或电缆。聚合物组合物层的形式可为单主绝缘层，双层电线结构的内层或外层，或多层结构中的任何一层。绝缘层也可以提供或代替用作单根电线或一束电线的绝缘电缆外层。例如，绝缘组合物可以通过挤压成型而包覆在电线上。
本发明还提供了自支承制品，例如中空制品，如由按照本发明第一方面的组合物制得的管状或枝状的模制品部件。
按照本发明的组合物较好地是可以交联的，因而可以是交联的。交联可以采用高能电子束或用过氧化物固化等已知方法来完成。在要将组合物用于电线或电缆时，较好是在组合物涂布在电线或电缆之后再进行交联。
已经发现，其中第一组分为聚酯或聚酯共混物优选组合物，尤其是那些本身就是或包含有聚酯/酯的优选组合物，特别符合电线包覆层的许多技术要求，而且加工方便又经济，这也是意想不到的。
实例1
包含有按照本发明聚合物组合物的铜导线由下列组分制得：
组分                         重量％
VALOX 325颗粒状               46
SILTEM 1500颗粒状             30
氢氧化镁                      20
STABOXOL P                    2
二氧化钛                      2
VALOX 325是可从通用电器公司购得的聚对苯二甲酸丁二醇酯。
SILTEM 1500是可从通用电器塑料公司购得的聚醚酰亚胺硅氧烷。
STABOXOL P是聚碳化二亚胺，作为水解稳定剂加入，而二氧化钛是作为颜料加入的。
将上述组分在120℃干燥至少4小时，随后将VALOX颗粒和SILTEM颗粒混合在一起，而粉末状的氢氧化镁、STABOXOL-P和二氧化钛同样也混合在一起。然后将这两种干混物各自进料到最高温度设定在250℃的双螺杆挤塑机的初始进料区中。物料在挤塑机中完全混合，将均匀的挤出物冷却和造粒，用于下一步加工。
将上述工艺中得到的颗粒在120℃干燥4小时，随后进料到最高温度设定在250℃的单螺杆挤塑机中。挤出的物料以20米/分的线速度包覆在18 AWG镀锡铜导线上从而形成绝缘层厚度等于0.25毫米(0.01英寸)的绝缘电线。
实例2
按类似于实例1所述方法，用下列组分制备聚合物组合物：
组分                        重量％
Elastotec E5511             36.63
Siltem 1300                 29.70
氢氧化镁                    29.70
Irgranox 1010(抗氧剂)        0.99
Staboxol P                   1.98
二氧化钛(任选)               1.00
Elastotec材料是含聚对苯二甲酸丁二醇酯硬段和聚己内酯软段的聚酯嵌段共聚物，可以从Elastogran GmbH(BASF的一个子公司)购得。
实例3双层电线包覆层
A：实例1和实例2的组合物各自以本身已知的方法经挤压包覆到已经带有0.15毫米厚的高密度聚乙烯包覆层的电线上，高密度聚乙烯层含常规数量的常用电线包覆用的添加剂，如抗氧剂、金属减活化剂、颜料等。结果使电线具有高密度聚乙烯的主芯绝缘层和分别为实例1和实例2组合物的，也是0.15毫米厚的主外层。此类电线非常适合那些不要求外层与芯层粘连在一起的应用场合。
B：重复A，用类似的聚对苯二甲酸丁二醇酯包覆层代替高密度聚乙烯芯包覆层。这样生产的电线其外层与芯层粘连在一起。
实例4
按类似于实例1所述方法，用“Armitel”(商标)UM 550(一种可以从Akzo Plastics公司购得的热塑性聚酯-酯-尿烷)制备按照本发明的聚合物组合物。含有33份Armitel UM550，20份Siltem 1300，45份氢氧化镁和2份Staboxol-P的共混物，其L.O.I.为31％，以0.23毫米(0.009英寸)厚的单包覆层形式包覆在16 AWG电线上，在150℃下老化0.605×106秒(168小时＝1星期)后仍保持63％延伸率。
实例2的聚对苯二甲酸丁二醇酯/聚己内酯的聚酯酯原料是优选的，因为已经发现该原料允许含较高含量(例如大于30％重量)的阻燃剂氢氧化镁，并且在180℃烘箱中老化0.1908×106秒(53小时)后仍具有耐脆裂性。这一点是令人惊奇的，因为聚己内酯与聚对苯二甲酸丁二醇酯的共混物并不表现出此类耐脆裂性。也已经发现诸如“Hytrel”(商标)等聚醚酯嵌段共聚物容易发生脆裂，因此这种共聚物最好排除在本说明书中所用的术语聚酯之外。更可喜的是该聚合物组合物在进行老化后仍能保持超过100％的延伸率。
已经意想不到地发现芯层和外层共挤出(而不是顺序挤出)覆盖到电线上即使用所要求的指甲掐入试验(thumb-nail test)测试时也具有改善的绝缘层耐切割性。对于有实例2外层的优选高密度聚乙烯芯层而言，情况更是如此。
本发明的共混物表现出性能协同的改善，例如，可由下面的事实得到说明，54％聚对苯二甲酸丁二醇酯(PBT)和36％“Siltem”的共混物与10％稳定剂的原料(在“Hytrel”聚合物中有20％“Staboxol”)在150℃下老化0.605×106秒(168小时＝1星期)后仍保持104％的延伸率，而PBT或“Siltem”单独使用时(采用同样的稳定剂含量)，经过类似的老化后均只能保留低于50％的延伸率。当不使用“Siltem”时，上述实例2的“Elastotec”E 5511在老化后其延伸率严重受损。

Claims (13)

1.一种极限氧指数(L.O.I.)至少为27％，较好至少为28％，更好至少为29％的聚合物组合物，含有由(a)和(b)组成的共混物：
(a)第一组分，它是一种聚合物或一种聚合物的共混物，该聚合物或共混物
(I)在没有任何其它组分的存在时其L.O.I.至多为21％.，和
(II)基本上不含卤素；和
(b)至多40％重量(以组合物总重量计)的第二组分，它是聚酰亚胺-硅氧烷聚合物，较好是聚醚酰亚胺-硅氧烷聚合物。
2.按照权利要求1的组合物，含有至多35％重量，较好是至多25％重量的第二组分。
3.按照权利要求1或2的组合物，其中第一组分是聚酯或聚酯的共混物，较好是或含有聚酯/酯嵌段共聚物，
4.按照权利要求1、2或3的组合物，含有氢氧化镁，其含量较好地在10～50％(重量)范围。
5.按照权利要求4的组合物，该组合物在低于270℃，较好地在低于250℃温度下进行加工。
6.一种可交联的按照权利要求1～5中任何一项的组合物。
7.一种已交联的按照权利要求1～5中任何一项的组合物。
8.带有按照权利要求1～7中任何一项的聚合物组合物的绝缘层的电线或电缆。
9.带有在第一聚合物组合物的主芯绝缘层上覆盖有按照权利要求1～7中任何一项的组合物外层的电线或电缆。
10.按照权利要求9的有绝缘层的电线或电缆，其中芯层含有聚烯烃，较好是高密度聚乙烯。
11.按照权利要求9的有绝缘层的电线或电缆，其中芯层含有聚酯，较好是聚对苯二甲酸丁二醇酯。
12.按照权利要求9～11中任何一项的电线或电缆，其中芯层和外层由共挤出覆盖在电线或电缆上。
13.按照权利要求8～12中任何一项的有绝缘层的电线或电缆，其中该种或每一种聚合物组合物在组合物覆盖到电线或电缆上后就已经是交联的。
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