CN112812450A - 一种电缆用低烟无卤阻燃绝缘料 - Google Patents
一种电缆用低烟无卤阻燃绝缘料 Download PDFInfo
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- 239000003063 flame retardant Substances 0.000 title claims abstract description 50
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 title claims abstract description 48
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- AJGPQPPJQDDCDA-UHFFFAOYSA-N azanium;hydron;oxalate Chemical compound N.OC(=O)C(O)=O AJGPQPPJQDDCDA-UHFFFAOYSA-N 0.000 claims abstract description 23
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- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 claims abstract description 17
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- KUAZQDVKQLNFPE-UHFFFAOYSA-N thiram Chemical compound CN(C)C(=S)SSC(=S)N(C)C KUAZQDVKQLNFPE-UHFFFAOYSA-N 0.000 claims description 5
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- DXZMANYCMVCPIM-UHFFFAOYSA-L zinc;diethylphosphinate Chemical compound [Zn+2].CCP([O-])(=O)CC.CCP([O-])(=O)CC DXZMANYCMVCPIM-UHFFFAOYSA-L 0.000 description 2
- 229920000181 Ethylene propylene rubber Polymers 0.000 description 1
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- 229910000041 hydrogen chloride Inorganic materials 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
- 239000000347 magnesium hydroxide Substances 0.000 description 1
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- C08J9/12—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a physical blowing agent
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- C08J9/141—Hydrocarbons
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Abstract
本发明公开了一种电缆用低烟无卤阻燃绝缘料,包括三元乙丙橡胶胶料60‑66份、EVA橡胶胶料35‑40份,硅烷偶联剂5‑8份、填料8‑12份、氮化铝1‑3份、纳米二硫化钼2‑4份、氢氧化铝20‑30份、聚磷酸铵15‑30份、液态硅胶12‑18份、草酸氢铵6‑9份、尼龙纤维5‑10份、硫化剂4‑6份、抗老化剂7‑14份、发泡剂6‑7份和稳泡剂2‑3份。本发明通过三元乙丙橡胶胶料和EVA橡胶胶料复合作为基料并配以多种增强材料和阻燃材料,使电缆用料具有良好的阻燃绝缘性,且耐热性强,耐磨损,使用寿命大大提高,并提供了一种加工工艺,通过本工艺使阻燃绝缘料的整体性能大大提高,便于推广使用。
Description
技术领域
本发明涉及电缆用绝缘料领域,具体涉及一种电缆用低烟无卤阻燃绝缘料。
背景技术
电缆用绝缘料一般要求必须具有优良的耐长期热老化性能、耐辐照、电气性能稳定、阻燃性能及绝缘性能优等特点。目前常用的电缆用绝缘料的基料为聚乙烯、聚氯乙烯、乙丙橡胶等材料,但是,这些基料的主要缺点是容易着火燃烧引起火灾。而采用含卤素的阻燃聚氯乙烯,虽然具有一定的阻燃作用,但是,与采用聚烯烃等无卤基料相比,采用聚氯乙烯基料在燃烧时会产生有毒的氯化氢气体及大量烟雾,使人中毒和窒息,妨碍人们从火灾中撤离和灭火工作的进行,造成了生命和财产的损失。因此,现有的绝缘料基本上是采用无卤阻燃电缆用绝缘料,该绝缘料通常是在有机高分子基料中添加无机阻燃剂,如氢氧化铝,氢氧化镁等。
然而,仅仅通过添加无机阻燃剂来实现电缆用绝缘料的阻燃,其安全性仍不好保证,在绝缘料使用过程中不可避免地会出现老化破损现象,导致无机阻燃剂无法提供全面的安全防护,存在安全隐患,容易引发火灾,且不易发现,带来大的经济损失。
因此,发明一种电缆用低烟无卤阻燃绝缘料来解决上述问题很有必要。
发明内容
本发明的目的是提供一种电缆用低烟无卤阻燃绝缘料,通过三元乙丙橡胶胶料和EVA橡胶胶料复合作为基料,硅烷偶联剂作为增粘剂,提高基料的粘接强度、耐水、耐气候等性能,可膨胀石墨、纳米碳酸钙和陶瓷粉体作为填料增强基料的强度和整体性能,纳米二硫化钼提高材料的耐磨性能和吸附能力,氢氧化铝具有良好的阻燃性和绝缘性,聚磷酸铵具有防火性,液态硅胶配合草酸氢铵和尼龙纤维组成B组分具有优良的吸收性,且硫化后具有优异的抗撕裂强度、回弹性、抗变黄性、热稳定性和耐热老化性,草酸氢铵加热后释放二氧化碳和水,并释放氨气,能够有效隔绝火源和释放危险信号,以解决技术中的上述不足之处。
为了实现上述目的,本发明提供如下技术方案:一种电缆用低烟无卤阻燃绝缘料,其中所使用的主料按重量计包括:三元乙丙橡胶胶料60-66份、EVA橡胶胶料35-40份,硅烷偶联剂5-8份、填料8-12份、氮化铝1-3份、纳米二硫化钼2-4份、氢氧化铝20-30份、聚磷酸铵15-30份、液态硅胶12-18份、草酸氢铵6-9份、尼龙纤维5-10份、硫化剂4-6份、抗老化剂7-14份、发泡剂6-7份和稳泡剂2-3份;
所述填料由可膨胀石墨、纳米碳酸钙和陶瓷粉体组成,且可膨胀石墨、白炭黑和陶瓷粉体的体积比设置为可膨胀石墨:纳米碳酸钙:陶瓷粉体=1-2:2-3:1。
优选的,所述硅烷偶联剂设置为乙烯基硅烷、氨基硅烷和甲基丙烯酰氧基硅烷中的一种。
优选的,所述可膨胀石墨、白炭黑和陶瓷粉体均设置为纳米颗粒,所述尼龙纤维的平均长度设置为13mm。
优选的,所述硫化剂设置为秋兰姆,所述抗老化剂设置为紫外线吸收剂RMB和炭黑的混合物,所述紫外线吸收剂RMB和炭黑的混合物的质量比设置为紫外线吸收剂RMB:炭黑=1:1。
优选的,所述发泡剂设置为石油醚,所述稳泡剂设置为硅树脂聚醚乳液。
一种电缆用低烟无卤阻燃绝缘料的制备方法,具体操作步骤为:
步骤一:准备原料,按比例取三元乙丙橡胶胶料、EVA橡胶胶料、硅烷偶联剂、可膨胀石墨、纳米碳酸钙、陶瓷粉体、氮化铝、纳米二硫化钼、氢氧化铝、聚磷酸铵、液态硅胶、草酸氢铵、尼龙纤维、硫化剂、抗老化剂、发泡剂和稳泡剂,备用;
步骤二:制备A组份,将三元乙丙橡胶胶料和EVA橡胶胶料放入熔炉内融化混合,并加入硅烷偶联剂、可膨胀石墨、纳米碳酸钙、陶瓷粉体、氮化铝、纳米二硫化钼、氢氧化铝,搅拌均匀后将混合物料取出并依次加入准备好的硫化剂、抗老化剂、发泡剂和稳泡剂,再次搅拌均匀,高温氮气环境下静置熟化,制成A组份;
步骤三:胶料发泡成孔,使用搅拌设备对上述A组份进行搅拌,使A组份物料内部形成大量气泡,并同时使用振荡设备在混合胶料内部高频振荡,使大的气泡消除,随后将发泡均匀后的混合胶料放入硫化设备内高温硫化,制成发泡绝缘料;
步骤四:制备B组分,将聚磷酸铵、草酸氢铵和尼龙纤维倒入液态硅胶中,并搅拌均匀,制成B组分物料;
步骤五:发泡绝缘料与B组分物料组合,将发泡绝缘料在真空环境下挤压使其被压缩,并排出发泡气孔内空气,继续将空气排出,往真空容器内倒入B组分物料,之后将作用于发泡绝缘料上的压板松弛,B组分物料被吸入孔隙内,发泡绝缘料得以再次充盈;
步骤六:硫化成型,将上述发泡绝缘料取出,并将其放入低温硫化设备内对其低温硫化,生成阻燃绝缘料,进一步对其整形处理后形成成品并包装
优选的,所述步骤二中高温氮气环境的温度设置为110-120℃,静置时间设置为30-40min。
优选的,所述步骤三中高温硫化温度设置为145-155℃,高温硫化压力设置为0.4MPa。
优选的,所述步骤六中低温硫化在密闭室中进行,硫化温度设置为50-60℃,硫化时通入渗氮蒸汽。
在上述技术方案中,本发明提供的技术效果和优点:
1、通过三元乙丙橡胶胶料和EVA橡胶胶料复合作为基料,硅烷偶联剂作为增粘剂,提高基料的粘接强度、耐水、耐气候等性能,可膨胀石墨、纳米碳酸钙和陶瓷粉体作为填料增强基料的强度和整体性能,纳米二硫化钼提高材料的耐磨性能和吸附能力,氢氧化铝具有良好的阻燃性和绝缘性,聚磷酸铵具有防火性,液态硅胶配合草酸氢铵和尼龙纤维组成B组分具有优良的吸收性,且硫化后具有优异的抗撕裂强度、回弹性、抗变黄性、热稳定性和耐热老化性,草酸氢铵加热后释放二氧化碳和水,并释放氨气,能够有效隔绝火源和释放危险信号;
2、通过在本配方工艺下分别制备A组份和B组分,并对A组份高温硫化以及对A组份与B组份的组合物进行低温硫化,特别针对A组份硫化后的发泡结构,挤压排出材料中的空气后,将B组份均匀填充至发泡孔隙内部,并使用氮气充盈,提高材料的绝缘性能,低温硫化后使B组分凝固在A组份内部且不破坏草酸氢铵的基本性能,使A组份与B组份均匀填充后获得的材料具有高强度的同时,保证材料的韧性和弹性,使绝缘料耐拉伸、抗变形、不易老化,从而延长其使用寿命,避免因电缆用绝缘料在长时间使用后或局部破损带来的安全隐患,不仅提高了绝缘料的阻燃效果,还能在绝缘料受热过大或者火情发生前分解二氧化碳和氨气,一定程度上隔绝燃烧所需氧气,且具有气味提示的效果。
具体实施方式
为了使本领域的技术人员更好地理解本发明的技术方案,下面将对本发明作进一步的详细介绍。
实施例1:
本发明提供了一种电缆用低烟无卤阻燃绝缘料,其中所使用的主料按重量计包括:三元乙丙橡胶胶料60份、EVA橡胶胶料35份,硅烷偶联剂5份、填料8份、氮化铝1份、纳米二硫化钼2份、氢氧化铝20份、聚磷酸铵15份、液态硅胶12份、草酸氢铵6份、尼龙纤维5份、硫化剂4份、抗老化剂7份、发泡剂6份和稳泡剂2份;
所述填料由可膨胀石墨、纳米碳酸钙和陶瓷粉体组成,且可膨胀石墨、白炭黑和陶瓷粉体的体积比设置为可膨胀石墨:纳米碳酸钙:陶瓷粉体=1:2:1。
优选的,所述硅烷偶联剂设置为乙烯基硅烷。
优选的,所述可膨胀石墨、白炭黑和陶瓷粉体均设置为纳米颗粒,所述尼龙纤维的平均长度设置为13mm。
优选的,所述硫化剂设置为秋兰姆,所述抗老化剂设置为紫外线吸收剂RMB和炭黑的混合物,所述紫外线吸收剂RMB和炭黑的混合物的质量比设置为紫外线吸收剂RMB:炭黑=1:1。
优选的,所述发泡剂设置为石油醚,所述稳泡剂设置为硅树脂聚醚乳液。
一种电缆用低烟无卤阻燃绝缘料的制备方法,具体操作步骤为:
步骤一:准备原料,按比例取三元乙丙橡胶胶料、EVA橡胶胶料、硅烷偶联剂、可膨胀石墨、纳米碳酸钙、陶瓷粉体、氮化铝、纳米二硫化钼、氢氧化铝、聚磷酸铵、液态硅胶、草酸氢铵、尼龙纤维、硫化剂、抗老化剂、发泡剂和稳泡剂,备用;
步骤二:制备A组份,将三元乙丙橡胶胶料和EVA橡胶胶料放入熔炉内融化混合,并加入硅烷偶联剂、可膨胀石墨、纳米碳酸钙、陶瓷粉体、氮化铝、纳米二硫化钼、氢氧化铝,搅拌均匀后将混合物料取出并依次加入准备好的硫化剂、抗老化剂、发泡剂和稳泡剂,再次搅拌均匀,高温氮气环境下静置熟化,温度设置为110℃,静置时间设置为30min,制成A组份;
步骤三:胶料发泡成孔,使用搅拌设备对上述A组份进行搅拌,使A组份物料内部形成大量气泡,并同时使用振荡设备在混合胶料内部高频振荡,使大的气泡消除,随后将发泡均匀后的混合胶料放入硫化设备内高温硫化,温度设置为145℃,高温硫化压力设置为0.4MPa,制成发泡绝缘料;
步骤四:制备B组分,将聚磷酸铵、草酸氢铵和尼龙纤维倒入液态硅胶中,并搅拌均匀,制成B组分物料;
步骤五:发泡绝缘料与B组分物料组合,将发泡绝缘料在真空环境下挤压使其被压缩,并排出发泡气孔内空气,继续将空气排出,往真空容器内倒入B组分物料,之后将作用于发泡绝缘料上的压板松弛,B组分物料被吸入孔隙内,发泡绝缘料得以再次充盈;
步骤六:硫化成型,将上述发泡绝缘料取出,并将其放入低温硫化设备内对其低温硫化,低温硫化在密闭室中进行,硫化温度设置为50℃,硫化时通入渗氮蒸汽,生成阻燃绝缘料,进一步对其整形处理后形成成品并包装。
本实施例中制备的电缆用低烟无卤阻燃绝缘料质地均匀,内部结构致密,且具有良好的弹性和抗拉伸抗撕裂能力,在拉伸变形后能够记忆回弹,回弹后无褶皱和变形产生,在对其进行燃烧试验时,其耐热性优异,不易燃,且在明火上长时间灼烧后烟气产生量少,在对本实施例制备的低烟无卤阻燃绝缘料的物理性能进行测试后,结果显示:该绝缘料的抗拉强度为12.5MPa,拉断伸长率为301%,在35℃太阳曝晒30d后,绝缘料的拉伸强度变化率为-1.2%,同时测得其拉断伸长率变化率为-0.8%,20℃体积电阻率为3.7x1012Ω·m。
实施例2:
本发明提供了一种电缆用低烟无卤阻燃绝缘料,其中所使用的主料按重量计包括:三元乙丙橡胶胶料63份、EVA橡胶胶料38份,硅烷偶联剂6份、填料10份、氮化铝2份、纳米二硫化钼3份、氢氧化铝25份、聚磷酸铵20份、液态硅胶15份、草酸氢铵8份、尼龙纤维6份、硫化剂5份、抗老化剂10份、发泡剂6.5份和稳泡剂2.5份;
所述填料由可膨胀石墨、纳米碳酸钙和陶瓷粉体组成,且可膨胀石墨、白炭黑和陶瓷粉体的体积比设置为可膨胀石墨:纳米碳酸钙:陶瓷粉体=2:2:1。
优选的,所述硅烷偶联剂设置为氨基硅烷。
优选的,所述可膨胀石墨、白炭黑和陶瓷粉体均设置为纳米颗粒,所述尼龙纤维的平均长度设置为13mm。
优选的,所述硫化剂设置为秋兰姆,所述抗老化剂设置为紫外线吸收剂RMB和炭黑的混合物,所述紫外线吸收剂RMB和炭黑的混合物的质量比设置为紫外线吸收剂RMB:炭黑=1:1。
优选的,所述发泡剂设置为石油醚,所述稳泡剂设置为硅树脂聚醚乳液。
一种电缆用低烟无卤阻燃绝缘料的制备方法,具体操作步骤为:
步骤一:准备原料,按比例取三元乙丙橡胶胶料、EVA橡胶胶料、硅烷偶联剂、可膨胀石墨、纳米碳酸钙、陶瓷粉体、氮化铝、纳米二硫化钼、氢氧化铝、聚磷酸铵、液态硅胶、草酸氢铵、尼龙纤维、硫化剂、抗老化剂、发泡剂和稳泡剂,备用;
步骤二:制备A组份,将三元乙丙橡胶胶料和EVA橡胶胶料放入熔炉内融化混合,并加入硅烷偶联剂、可膨胀石墨、纳米碳酸钙、陶瓷粉体、氮化铝、纳米二硫化钼、氢氧化铝,搅拌均匀后将混合物料取出并依次加入准备好的硫化剂、抗老化剂、发泡剂和稳泡剂,再次搅拌均匀,高温氮气环境下静置熟化,温度设置为115℃,静置时间设置为35min,制成A组份;
步骤三:胶料发泡成孔,使用搅拌设备对上述A组份进行搅拌,使A组份物料内部形成大量气泡,并同时使用振荡设备在混合胶料内部高频振荡,使大的气泡消除,随后将发泡均匀后的混合胶料放入硫化设备内高温硫化,温度设置为150℃,高温硫化压力设置为0.4MPa,制成发泡绝缘料;
步骤四:制备B组分,将聚磷酸铵、草酸氢铵和尼龙纤维倒入液态硅胶中,并搅拌均匀,制成B组分物料;
步骤五:发泡绝缘料与B组分物料组合,将发泡绝缘料在真空环境下挤压使其被压缩,并排出发泡气孔内空气,继续将空气排出,往真空容器内倒入B组分物料,之后将作用于发泡绝缘料上的压板松弛,B组分物料被吸入孔隙内,发泡绝缘料得以再次充盈;
步骤六:硫化成型,将上述发泡绝缘料取出,并将其放入低温硫化设备内对其低温硫化,低温硫化在密闭室中进行,硫化温度设置为55℃,硫化时通入渗氮蒸汽,生成阻燃绝缘料,进一步对其整形处理后形成成品并包装。
对比实施例1,本实施例中制备的电缆用低烟无卤阻燃绝缘料质地均匀,内部结构致密,且具有良好的弹性和抗拉伸抗撕裂能力,在拉伸变形后能够记忆回弹,回弹后无褶皱和变形产生,在对其进行燃烧试验时,其耐热性优异,不易燃,且在明火上长时间灼烧后烟气产生量少,在对本实施例制备的低烟无卤阻燃绝缘料的物理性能进行测试后,结果显示:该绝缘料的抗拉强度为13.3MPa,拉断伸长率为315%,在35℃太阳曝晒30d后,绝缘料的拉伸强度变化率为-0.6%,同时测得其拉断伸长率变化率为-0.2%,20℃体积电阻率为4.5x1012Ω·m。
实施例3:
本发明提供了一种电缆用低烟无卤阻燃绝缘料,其中所使用的主料按重量计包括:三元乙丙橡胶胶料66份、EVA橡胶胶料40份,硅烷偶联剂8份、填料12份、氮化铝3份、纳米二硫化钼4份、氢氧化铝30份、聚磷酸铵30份、液态硅胶18份、草酸氢铵9份、尼龙纤维10份、硫化剂6份、抗老化剂14份、发泡剂7份和稳泡剂3份;
所述填料由可膨胀石墨、纳米碳酸钙和陶瓷粉体组成,且可膨胀石墨、白炭黑和陶瓷粉体的体积比设置为可膨胀石墨:纳米碳酸钙:陶瓷粉体=2:3:1。
优选的,所述硅烷偶联剂设置为甲基丙烯酰氧基硅烷。
优选的,所述可膨胀石墨、白炭黑和陶瓷粉体均设置为纳米颗粒,所述尼龙纤维的平均长度设置为13mm。
优选的,所述硫化剂设置为秋兰姆,所述抗老化剂设置为紫外线吸收剂RMB和炭黑的混合物,所述紫外线吸收剂RMB和炭黑的混合物的质量比设置为紫外线吸收剂RMB:炭黑=1:1。
优选的,所述发泡剂设置为石油醚,所述稳泡剂设置为硅树脂聚醚乳液。
一种电缆用低烟无卤阻燃绝缘料的制备方法,具体操作步骤为:
步骤一:准备原料,按比例取三元乙丙橡胶胶料、EVA橡胶胶料、硅烷偶联剂、可膨胀石墨、纳米碳酸钙、陶瓷粉体、氮化铝、纳米二硫化钼、氢氧化铝、聚磷酸铵、液态硅胶、草酸氢铵、尼龙纤维、硫化剂、抗老化剂、发泡剂和稳泡剂,备用;
步骤二:制备A组份,将三元乙丙橡胶胶料和EVA橡胶胶料放入熔炉内融化混合,并加入硅烷偶联剂、可膨胀石墨、纳米碳酸钙、陶瓷粉体、氮化铝、纳米二硫化钼、氢氧化铝,搅拌均匀后将混合物料取出并依次加入准备好的硫化剂、抗老化剂、发泡剂和稳泡剂,再次搅拌均匀,高温氮气环境下静置熟化,温度设置为120℃,静置时间设置为40min,制成A组份;
步骤三:胶料发泡成孔,使用搅拌设备对上述A组份进行搅拌,使A组份物料内部形成大量气泡,并同时使用振荡设备在混合胶料内部高频振荡,使大的气泡消除,随后将发泡均匀后的混合胶料放入硫化设备内高温硫化,温度设置为155℃,高温硫化压力设置为0.4MPa,制成发泡绝缘料;
步骤四:制备B组分,将聚磷酸铵、草酸氢铵和尼龙纤维倒入液态硅胶中,并搅拌均匀,制成B组分物料;
步骤五:发泡绝缘料与B组分物料组合,将发泡绝缘料在真空环境下挤压使其被压缩,并排出发泡气孔内空气,继续将空气排出,往真空容器内倒入B组分物料,之后将作用于发泡绝缘料上的压板松弛,B组分物料被吸入孔隙内,发泡绝缘料得以再次充盈;
步骤六:硫化成型,将上述发泡绝缘料取出,并将其放入低温硫化设备内对其低温硫化,低温硫化在密闭室中进行,硫化温度设置为60℃,硫化时通入渗氮蒸汽,生成阻燃绝缘料,进一步对其整形处理后形成成品并包装。
对比实施例1和2,本实施例中制备的电缆用低烟无卤阻燃绝缘料质地均匀,内部结构致密,且具有良好的弹性和抗拉伸抗撕裂能力,在拉伸变形后能够记忆回弹,回弹后无褶皱和变形产生,在对其进行燃烧试验时,其耐热性优异,不易燃,且在明火上长时间灼烧后烟气产生量少,在对本实施例制备的低烟无卤阻燃绝缘料的物理性能进行测试后,结果显示:该绝缘料的抗拉强度为13.0MPa,拉断伸长率为312%,在35℃太阳曝晒30d后,绝缘料的拉伸强度变化率为-0.8%,同时测得其拉断伸长率变化率为-0.5%,20℃体积电阻率为4.4x1012Ω·m。
根据实施例1-3得出下表:
由上表可知,实施例2中原材料比例适中,加工温度适中,采用该配方胶料制成的电缆绝缘料通过相应标准中规定的单根垂直燃烧试验,电绝缘性能和物理性能完全满足要求,且实施例1-3相比,实施例2中的工艺得到的电缆绝缘料性能最优,适宜推广和使用,并且使用三元乙丙橡胶胶料和EVA橡胶胶料复合作为基料,硅烷偶联剂作为增粘剂,提高基料的粘接强度、耐水、耐气候等性能,并加以可膨胀石墨、纳米碳酸钙和陶瓷粉体作为填料增强基料的强度和整体性能,经过表面改性处理后的纳米碳酸钙与橡胶有很好的相容性,具有补强、填充、调色、改善加工艺和制品的性能,可使橡胶易混炼、易分散,混炼后胶质柔软,橡胶表面光滑,可使制品的延伸性、抗张强度、撕裂强度等有本质的提高,氮化铝赋予材料耐高温、抗冲击和导热性好的特征,纳米二硫化钼具有比表面积大、吸附能力强和反应活性高的特点,能够在摩擦副表面的附着性与覆盖程度明显提高,提高材料的耐磨性能和吸附能力,氢氧化铝具有良好的阻燃性和绝缘性,聚磷酸铵具有防火性,液态硅胶具有优异的抗撕裂强度、回弹性、抗变黄性、热稳定性和耐热老化性,草酸氢铵加热后释放二氧化碳和水,并释放氨气,能够有效隔绝火源和释放危险信号,在生产时,分别制备A组份和B组分,并对A组份高温硫化以及对A组份与B组份的组合物进行低温硫化,特别针对A组份硫化后的发泡结构,挤压排出材料中的空气后,将B组份均匀填充至发泡孔隙内部,并使用氮气充盈,提高材料的绝缘性能,低温硫化后使B组分凝固在A组份内部且不破坏草酸氢铵的基本性能,使A组份与B组份均匀填充后获得的材料具有高强度的同时,保证材料的韧性和弹性,使绝缘料耐拉伸、抗变形、不易老化,从而延长其使用寿命,避免因电缆用绝缘料在长时间使用后或局部破损带来的安全隐患,不仅提高了绝缘料的阻燃效果,还能在绝缘料受热过大或者火情发生前分解二氧化碳和氨气,一定程度上隔绝燃烧所需氧气,且具有气味提示的效果。
以上只通过说明的方式描述了本发明的某些示范性实施例,毋庸置疑,对于本领域的普通技术人员,在不偏离本发明的精神和范围的情况下,可以用各种不同的方式对所描述的实施例进行修正。因此,上述描述在本质上是说明性的,不应理解为对本发明权利要求保护范围的限制,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (9)
1.一种电缆用低烟无卤阻燃绝缘料,其特征在于:其中所使用的主料按重量计包括:三元乙丙橡胶胶料60-66份、EVA橡胶胶料35-40份,硅烷偶联剂5-8份、填料8-12份、氮化铝1-3份、纳米二硫化钼2-4份、氢氧化铝20-30份、聚磷酸铵15-30份、液态硅胶12-18份、草酸氢铵6-9份、尼龙纤维5-10份、硫化剂4-6份、抗老化剂7-14份、发泡剂6-7份和稳泡剂2-3份;
所述填料由可膨胀石墨、纳米碳酸钙和陶瓷粉体组成,且可膨胀石墨、白炭黑和陶瓷粉体的体积比设置为可膨胀石墨:纳米碳酸钙:陶瓷粉体=1-2:2-3:1。
2.根据权利要求1所述的一种电缆用低烟无卤阻燃绝缘料,其特征在于:所述硅烷偶联剂设置为乙烯基硅烷、氨基硅烷和甲基丙烯酰氧基硅烷中的一种。
3.根据权利要求1所述的一种电缆用低烟无卤阻燃绝缘料,其特征在于:所述可膨胀石墨、白炭黑和陶瓷粉体均设置为纳米颗粒,所述尼龙纤维的平均长度设置为13mm。
4.根据权利要求1所述的一种电缆用低烟无卤阻燃绝缘料,其特征在于:所述硫化剂设置为秋兰姆,所述抗老化剂设置为紫外线吸收剂RMB和炭黑的混合物,所述紫外线吸收剂RMB和炭黑的混合物的质量比设置为紫外线吸收剂RMB:炭黑=1:1。
5.根据权利要求1所述的一种电缆用低烟无卤阻燃绝缘料,其特征在于:所述发泡剂设置为石油醚,所述稳泡剂设置为硅树脂聚醚乳液。
6.根据权利要求1-5中任意一项所述的一种电缆用低烟无卤阻燃绝缘料的制备方法,其特征在于:具体操作步骤为:
步骤一:准备原料,按比例取三元乙丙橡胶胶料、EVA橡胶胶料、硅烷偶联剂、可膨胀石墨、纳米碳酸钙、陶瓷粉体、氮化铝、纳米二硫化钼、氢氧化铝、聚磷酸铵、液态硅胶、草酸氢铵、尼龙纤维、硫化剂、抗老化剂、发泡剂和稳泡剂,备用;
步骤二:制备A组份,将三元乙丙橡胶胶料和EVA橡胶胶料放入熔炉内融化混合,并加入硅烷偶联剂、可膨胀石墨、纳米碳酸钙、陶瓷粉体、氮化铝、纳米二硫化钼、氢氧化铝,搅拌均匀后将混合物料取出并依次加入准备好的硫化剂、抗老化剂、发泡剂和稳泡剂,再次搅拌均匀,高温氮气环境下静置熟化,制成A组份;
步骤三:胶料发泡成孔,使用搅拌设备对上述A组份进行搅拌,使A组份物料内部形成大量气泡,并同时使用振荡设备在混合胶料内部高频振荡,使大的气泡消除,随后将发泡均匀后的混合胶料放入硫化设备内高温硫化,制成发泡绝缘料;
步骤四:制备B组分,将聚磷酸铵、草酸氢铵和尼龙纤维倒入液态硅胶中,并搅拌均匀,制成B组分物料;
步骤五:发泡绝缘料与B组分物料组合,将发泡绝缘料在真空环境下挤压使其被压缩,并排出发泡气孔内空气,继续将空气排出,往真空容器内倒入B组分物料,之后将作用于发泡绝缘料上的压板松弛,B组分物料被吸入孔隙内,发泡绝缘料得以再次充盈;
步骤六:硫化成型,将上述发泡绝缘料取出,并将其放入低温硫化设备内对其低温硫化,生成阻燃绝缘料,进一步对其整形处理后形成成品并包装。
7.根据权利要求6所述的一种电缆用低烟无卤阻燃绝缘料的制备方法,其特征在于:所述步骤二中高温氮气环境的温度设置为110-120℃,静置时间设置为30-40min。
8.根据权利要求6所述的一种电缆用低烟无卤阻燃绝缘料的制备方法,其特征在于:所述步骤三中高温硫化温度设置为145-155℃,高温硫化压力设置为0.4MPa。
9.根据权利要求6所述的一种电缆用低烟无卤阻燃绝缘料的制备方法,其特征在于:所述步骤六中低温硫化在密闭室中进行,硫化温度设置为50-60℃,硫化时通入渗氮蒸汽。
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