CN112366033B - 一种轻质高压气体阻燃电缆用填充 - Google Patents

一种轻质高压气体阻燃电缆用填充 Download PDF

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CN112366033B
CN112366033B CN202011250734.7A CN202011250734A CN112366033B CN 112366033 B CN112366033 B CN 112366033B CN 202011250734 A CN202011250734 A CN 202011250734A CN 112366033 B CN112366033 B CN 112366033B
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王振金
张海平
王焱
丁博
陈颖
唐国强
张信
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Hunan Valin Wire and Cable Co Ltd
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Abstract

本发明公开了一种轻质高压气体阻燃电缆用填充，包括基材、孔隙和玻纤带，所述基材为EPE珍珠棉，所述基材的表面覆盖玻纤带，所述基材上具有多个孔隙，所述孔隙中充满CO2气体，本发明中的轻质高压气体阻燃电缆用填充质量轻，减少了电缆重量，同时阻燃性能明显提高，当火灾时，高温可使EPE的聚乙烯熔化，高压CO2释放，具有灭火功效，其最外层的玻纤带在高温时形成膜进一步阻隔氧气，阻燃效果好。

Description

一种轻质高压气体阻燃电缆用填充
技术领域
本发明涉及电缆技术领域，尤其涉及一种轻质高压气体阻燃电缆用填充。
背景技术
电缆填充用于填充电缆中的缝隙，目前电缆用填充大多采用PP绳、无机绳、(橡皮、塑料)垫芯条。由于现在多数填充密度大，其制作成本较高，且会导致电缆质量较重，会对电缆的使用造成不良影响，特别是在般天、船舶、武器装备等用电缆有严格的重量要求的场合，不仅如此，现在大多填充没有阻燃效果，且填充(特别是阻燃填充)大多可变形性差，无法填满缝隙，导致电缆外形不圆整，影响美观和使用。
发明内容
本发明的目的是为了解决现有技术中电缆填充质量重、阻燃性差的问题，而提出的一种轻质高压气体阻燃电缆用填充。
为了实现上述目的，本发明采用了如下技术方案：
一种轻质高压气体阻燃电缆用填充，包括基材、孔隙和玻纤带，所述基材的表面覆盖玻纤带，所述基材上具有多个孔隙，所述孔隙中充满CO2气体，CO2气体具有阻燃的效果。
进一步的，所述基材为30-40倍高发泡的EPE珍珠棉。
进一步的，所述孔隙中的CO2气体的压强为2-3个大气压强，高压CO2气体可使基材1不易变形。
进一步的，所述玻纤带的厚度为0.05mm。
所述基材的制备过程包括以下步骤：
步骤S1：按照重量比将基材的原料备好，并将其投入搅拌机中混合均匀，得到混合基料。本发明中的基材中EPE珍珠棉包括以下重量百分比的原料：低密度聚乙烯82％、四[β-(3，5-二叔丁基-4-羟基苯基)丙酸]季戊四醇酯0.8％、POE塑料(乙烯辛烯共聚物)8％、滑石粉5％、硬酸酯0.5-1％、MgO 1-2％、三聚氰胺1-1.5％、磷酸三苯酚1.5-2％。
步骤S2：将混合基料经由自动上料机均匀的送入挤出机；
步骤S3：挤出机通过螺标剪切及加热将混合基料进行融熔，挤出温区控制在90-180℃之间，挤出腔内部整体的温度分布保持中部温度高于两端温度的状态；
步骤S4：采用1.5MPa的高压N2将液化CO2和单甘脂送进机筒，其中液化CO2通过CO2泵进行输送，单甘脂泵通过单甘脂泵进行输送，CO2泵和单甘脂泵的进料部位设有单向阀，使原料不致反向倒流，以确保生产安全。
本步骤包括CO2发泡过程，发泡原理为高压液化CO2气化发泡，系物理发泡，与化学发泡比无污染。传统物理发泡中发泡剂常用丁烷，本发明中的CO2气化发泡相比于传统物理发泡中丁烷比更安全。另外，CO2可行性的重点在于相比于其他气体，其沸点相对高、易液化。
步骤S5：挤出后，混合基料在0.2-0.3MPaD的N2保压管中冷却成型，使其气孔中CO2保证有2-3个大气压，得到EPE珍珠棉管。本所述步骤S5中，成型后的EPE棉管的冷却包括以下步骤：
步骤A1：成型后的EPE棉管通过超声波加湿器迅速进行冷却，用于稳定棉管的相关参数，并且进行二次物理降温，使得棉管的物理性能更稳定；
步骤A2：从超声波加湿器出来的EPE棉管通过牵引辊，此时牵引速度应保持均衡，以保证棉管质量，牵引辊装有变频调速的电动机，可以随时调整牵引速度；
步骤A3：通过牵引辊出来的EPE棉管，进入风冷装置，进一步对棉管进行再次冷却成型。
本发明中的EPE棉管使用超声波加湿器迅速冷却步骤和风冷装置冷却步骤后，进入自动载切计数工序，采用变频控制，其速度可以在触模屏人机界面上设置裁切长度和计数，得到目标长度和数量的EPE棉管。
本发明的有益效果是：
1、本轻质高压气体阻燃电缆用填充密度仅为0.03g/cm3，比原较比PP填充绳(密度为0.9g/cm3)对比下降了300倍，填充质量轻，减少了电缆重量；同时阻燃性能明显提高，当火灾时，高温使EPE的聚乙烯熔化，2-3个大气压高压CO2释放，就如同在电缆中增加了CO2灭火器，具有灭火功效；其最外层的玻纤带在高温时形成膜进一步阻隔氧气，阻燃效果好。
2、本轻质高压气体阻燃电缆用填充因基材中的孔隙相互独立，且其材料为聚乙烯基材，完全满足电缆标准中的非吸湿性材料要求。
3、本发明中的高压液化CO2气化发泡，系物理发泡，与化学发泡比无污染，且相比于传统物理发泡中丁烷比更安全。
附图说明
图1为本轻质高压气体阻燃电缆用填充的结构示意图；
图2为本轻质高压气体阻燃电缆用填充中基材制备流程图。
图中：1、基材；2、孔隙；3、玻纤带。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。
参照图1，一种轻质高压气体阻燃电缆用填充，包括基材1、孔隙2和玻纤带3，所述基材1的表面覆盖玻纤带3，所述基材1上具有多个孔隙2，所述孔隙2中充满CO2气体，CO2气体具有阻燃的效果。
进一步的，所述基材1为30-40倍高发泡的EPE珍珠棉。
进一步的，所述孔隙2中的CO2气体的压强为2-3个大气压强，高压CO2气体可使基材1不易变形，CO2气体在基材1的物理发泡过程中充入孔隙2。
进一步的，所述玻纤带3的厚度为0.05mm。
参考图2，所述基材(1)的制备过程包括以下步骤：
步骤S1：按照重量比将基材的原料备好，并将其投入搅拌机中混合均匀，得到混合基料。本发明中的基材中EPE珍珠棉包括以下重量百分比的原料：低密度聚乙烯82％、四[β-(3，5-二叔丁基-4-羟基苯基)丙酸]季戊四醇酯0.8％、POE塑料(乙烯辛烯共聚物)8％、滑石粉5％、硬酸酯0.5-1％、MgO 1-2％、三聚氰胺1-1.5％、磷酸三苯酚1.5-2％。
步骤S2：将混合基料经由自动上料机均匀的送入挤出机；
步骤S3：挤出机通过螺标剪切及加热将混合基料进行融熔，挤出温区控制在90-180℃之间，挤出腔内部整体的温度分布保持中部温度高于两端温度的状态；
步骤S4：采用1.5MPa的高压N2将液化CO2和单甘脂送进机筒，其中液化CO2通过CO2泵进行输送，单甘脂泵通过单甘脂泵进行输送，CO2泵和单甘脂泵的进料部位设有单向阀，使原料不致反向倒流，以确保生产安全。
本步骤包括CO2发泡过程，发泡原理为高压液化CO2气化发泡，系物理发泡，与化学发泡比无污染。传统物理发泡中发泡剂常用丁烷，本发明中的CO2气化发泡相比于传统物理发泡中丁烷比更安全。另外，CO2可行性的重点在于相比于其他气体，其沸点相对高、易液化。
步骤S5：挤出后，混合基料在0.2-0.3MPaD的N2保压管中冷却成型，使其气孔中CO2保证有2-3个大气压，得到EPE珍珠棉管。本所述步骤S5中，成型后的EPE棉管的冷却包括以下步骤：
步骤A1：成型后的EPE棉管通过超声波加湿器迅速进行冷却，用于稳定棉管的相关参数，并且进行二次物理降温，使得棉管的物理性能更稳定；
步骤A2：从超声波加湿器出来的EPE棉管通过牵引辊，此时牵引速度应保持均衡，以保证棉管质量，牵引辊装有变频调速的电动机，可以随时调整牵引速度；
步骤A3：通过牵引辊出来的EPE棉管，进入风冷装置，进一步对棉管进行再次冷却成型。
本实施例中中的EPE棉管使用超声波加湿器迅速冷却步骤和风冷装置冷却步骤后，进入自动载切计数工序，采用变频控制，其速度可以在触模屏人机界面上设置裁切长度和计数，得到目标长度和数量的EPE棉管，然后去静电和包装。
本实施例中的轻质高压气体阻燃电缆用填充密度仅为0.03g/cm3，比原较比PP填充绳(密度为0.9g/cm3)对比下降了300倍，填充质量轻，减少了电缆重量，同时阻燃性能明显提高，当火灾时，高温使EPE的聚乙烯熔化，2-3个大气压高压CO2释放，就如同在电缆中增加了CO2灭火器，具有灭火功效，其最外层的玻纤带3在高温时形成膜进一步阻隔氧气，阻燃效果好；且本轻质高压气体阻燃电缆用填充因基材1中的孔隙2相互独立，且其材料为聚乙烯基材，完全满足电缆标准中的非吸湿性材料要求。
以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明揭露的技术范围内，根据本发明的技术方案及其发明构思加以等同替换或改变，都应涵盖在本发明的保护范围之内。

Claims (5)

1.一种轻质高压气体阻燃电缆用填充，其特征在于，包括基材（1）、孔隙（2）和玻纤带（3），所述基材（1）的表面覆盖玻纤带（3），所述基材（1）上具有多个孔隙（2），所述孔隙（2）中充满CO2气体；
所述基材（1）为30-40 倍高发泡的EPE珍珠棉；
所述基材（1）的制备过程包括以下步骤：
S1：按照重量比将基材（1）的原料备好，并将其投入搅拌机中混合均匀，得到混合基料；
S2：将混合基料经由自动上料机均匀的送入挤出机；
S3：挤出机通过螺标剪切及加热将混合基料进行融熔，挤出温区控制在90-180℃之间，挤出腔内部整体的温度分布保持中部温度高于两端温度的状态；
S4：采用1.5MPa的高压N2将液化CO2和单甘脂送进挤出机机筒；
S5：挤出后，混合基料在0.2-0.3MPaD的N2保压管中冷却成型，其孔隙中CO2保证有2-3个大气压。
2.根据权利要求1所述的一种轻质高压气体阻燃电缆用填充，其特征在于，所述玻纤带（3）的厚度为0.05mm。
3.根据权利要求2所述的一种轻质高压气体阻燃电缆用填充，其特征在于，所述基材（1）中EPE珍珠棉包括以下重量百分比的原料：低密度聚乙烯82%、四[β-(3，5-二叔丁基-4-羟基苯基)丙酸]季戊四醇酯0.8%、POE塑料（乙烯辛烯共聚物）8% 、滑石粉5%、硬酸酯0.5-1%、MgO 1-2%、三聚氰胺1-1.5% 、磷酸三苯酚1.5-2%。
4.根据权利要求3所述的一种轻质高压气体阻燃电缆用填充，其特征在于，所述步骤S4中，CO2泵和单甘脂泵的进料部位设有单向阀。
5.根据权利要求3所述的一种轻质高压气体阻燃电缆用填充，其特征在于，所述步骤S5中，成型后的EPE棉管的冷却包括使用超声波加湿器迅速冷却步骤和风冷装置冷却步骤。
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