CN114121342B - 一种风力发电用耐扭曲软电缆 - Google Patents
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Abstract
本发明公开了一种风力发电用耐扭曲软电缆，包括：导体；包覆在所述导体外部的绝缘层；包覆在所述绝缘层外部的屏蔽层；和包覆在所述屏蔽层外部的护套层；其中绝缘层由下述质量份的原料制成：三元乙丙橡胶90‑100份、EVA‑g‑GMA 5‑10份、炭黑30‑40份、白炭黑10‑15份、硅烷偶联剂KH‑560改性纳米蒙脱土5‑10份、环氧大豆油5‑10份、硫化剂6‑10份、氧化锌5‑8份、防老剂1‑2份、氯化石蜡1‑2份。本发明的电缆具有优良的耐扭曲性，可以减少变形、开裂，延长使用寿命，尤其适合在风电机舱内部使用。
Description
技术领域
本发明涉及先进制造技术领域，尤其涉及一种风力发电用耐扭曲软电缆。
背景技术
当前，能源和环境之间的关系已经成为全世界共同关注的焦点。风能是一种清洁无公害的可再生能源，蕴量巨大，用之不竭，风力发电具有绿色环保、可持续性好的优点。因此，风力发电的开发也成为我国社会经济发展的重点。风电机组需要使用大量电力电缆、数据与控制电缆和通信电缆，这些电缆决定了电网和通信系统的互连质量。由于风场往往位于强风气候条件的恶劣环境中，对这些电缆的性能提出了更高的要求，尤其是对于位于风电机舱内部的电缆来说，为了避免电缆发生变形、开裂，延长电缆的使用寿命，需要具有优异的扭转和弯曲柔韧性。
发明内容
基于背景技术存在的技术问题，本发明提出了一种风力发电用耐扭曲软电缆。
本发明提出的一种风力发电用耐扭曲软电缆，包括：导体；包覆在所述导体外部的绝缘层；包覆在所述绝缘层外部的屏蔽层；和包覆在所述屏蔽层外部的护套层；
所述绝缘层由下述质量份的原料制成：三元乙丙橡胶90-100份、EVA-g-GMA5-10份、炭黑30-40份、白炭黑10-15份、硅烷偶联剂KH-560改性蒙脱土5-10份、环氧大豆油5-10份、硫化剂6-10份、氧化锌5-8份、防老剂1-2份、氯化石蜡1-2份。
优选地，所述EVA-g-GMA的制备方法为：将EVA树脂、甲基丙烯酸缩水甘油酯和引发剂加入密炼机中，在120-150℃下熔融接枝10-30min，即得。
优选地，所述EVA树脂、甲基丙烯酸缩水甘油酯的质量比为100：(10-20)；所述甲基丙烯酸缩水甘油酯、引发剂的质量比为10：(0.5-1)。
优选地，所述引发剂为过氧化二异丙苯、过氧化苯甲酰、过氧化二叔丁基中的至少一种。
优选地，所述硅烷偶联剂KH-560改性蒙脱土是以硅烷偶联剂KH-560对蒙脱土进行表面改性得到，优选地，所述蒙脱土与硅烷偶联剂KH-560的质量比为1：(0.1-0.2)。
优选地，所述硅烷偶联剂KH-560改性蒙脱土的制备方法为：将硅烷偶联剂KH-560、乙醇和水按质量比为1：(20-50)：(2-5)混合均匀，然后加入蒙脱土，在60-90℃下搅拌反应1-3h，过滤、干燥，即得。
优选地，所述护套层由下述质量份的原料制成：氯丁橡胶40-55份、氟硅橡胶5-10份、氯化聚乙烯30-40份、炭黑15-20份、氧化镁10-15份、氧化锌3-5份、气相二氧化硅3-5份、无机阻燃剂25-30份、环氧硬脂酸丁酯3-5份、硫化剂5-8份、硅烷偶联剂1-2份、防老剂1-2份、氯化石蜡0.5-1份。
优选地，所述硫化剂为硫化剂DCP、硫化剂DTDM或其组合；所述防老剂为防老剂RD、防老剂IPPD、防老剂6PPD中的至少一种；所述无机阻燃剂为三氧化二锑、氢氧化镁或其组合。
优选地，所述导体由多股软铜线绞合成形而成。
优选地，所述屏蔽层由镀锡铜丝编织而成，编织密度≥85％。
本发明的有益效果如下：
本发明电缆的导体使用多股软铜线绞合成形，使电缆更具有柔软、耐扭转、耐弯曲等特点；绝缘层采用三元乙丙橡胶和EVA-g-GMA配合作为基体树脂，一方面，适量EVA-g-GMA的添加可以提高绝缘层材料的加工性能，另一方面，GMA的接枝引入了环氧基团，与表面含环氧基团的蒙脱土填充料之间粘结力增强，既有利于提高材料的韧性，又使蒙脱土在基体树脂中的分散更为均匀，有利于提高绝缘层的绝缘性，从而得到绝缘性好、耐弯曲韧性强且加工性好的绝缘层。屏蔽层采用编织密度大于85％的镀锡铜丝编织屏蔽，可以提高产品抗干扰性能；护套层以氯丁橡胶、氟硅橡胶和氯化聚乙烯配合作为基体树脂，辅以合适的填充料和助剂，使电缆护套层不仅弯曲柔韧性高，而且具有良好的阻燃性能、防老化性能和防腐性能，延长电缆的使用寿命。本发明的电缆具有良好的耐低温、耐扭转、耐疲劳性、耐候老化性能，电缆在恶劣的环境中也能长时间不开裂，延长了电缆的使用寿命，尤其适合在风电机舱内部使用。
具体实施方式
下面，通过具体实施例对本发明的技术方案进行详细说明。
下述实施例和对比例中，所用的三元乙丙橡胶为埃克森2504；EVA树脂为杜邦420；炭黑为炭黑N550。
实施例1
一种风力发电用耐扭曲软电缆，包括：导体，其中导体由多股软铜线绞合成形而成；包覆在所述导体外部的绝缘层；包覆在所述绝缘层外部的屏蔽层，其中屏蔽层由镀锡铜丝编织而成，编织密度≥85％；和包覆在所述屏蔽层外部的护套层。
绝缘层由下述质量份的原料制成：三元乙丙橡胶95份、EVA-g-GMA 8份、炭黑35份、白炭黑12份、硅烷偶联剂KH-560改性蒙脱土8份、环氧大豆油8份、硫化剂DCP 8份、氧化锌6份、防老剂RD 1.5份、氯化石蜡1.5份；EVA-g-GMA的制备方法为：将EVA树脂、甲基丙烯酸缩水甘油酯和过氧化苯甲酰加入密炼机中，在140℃下熔融接枝20min，即得，其中EVA树脂、甲基丙烯酸缩水甘油酯的质量比为100：15，甲基丙烯酸缩水甘油酯、过氧化苯甲酰的质量比为10：0.8；硅烷偶联剂KH-560改性蒙脱土的制备方法为：将硅烷偶联剂KH-560、乙醇和水按质量比为1：40：4混合均匀，然后加入蒙脱土，在85℃下搅拌反应2h，过滤、干燥，即得，其中蒙脱土与硅烷偶联剂KH-560的质量比为1：0.15。
护套层由下述质量份的原料制成：氯丁橡胶50份、氟硅橡胶8份、氯化聚乙烯35份、炭黑18份、氧化镁12份、氧化锌4份、气相二氧化硅4份、氢氧化镁28份、环氧硬脂酸丁酯4份、硫化剂DCP 6份、硅烷偶联剂KH550 1.5份、防老剂RD 1.5份、氯化石蜡0.6份。
实施例2
一种风力发电用耐扭曲软电缆，包括：导体，其中导体由多股软铜线绞合成形而成；包覆在所述导体外部的绝缘层；包覆在所述绝缘层外部的屏蔽层，其中屏蔽层由镀锡铜丝编织而成，编织密度≥85％；和包覆在所述屏蔽层外部的护套层。
绝缘层由下述质量份的原料制成：三元乙丙橡胶90份、EVA-g-GMA 5份、炭黑30份、白炭黑10份、硅烷偶联剂KH-560改性蒙脱土5份、环氧大豆油5份、硫化剂DCP 6份、氧化锌5份、防老剂RD 1份、氯化石蜡1份；EVA-g-GMA的制备方法为：将EVA树脂、甲基丙烯酸缩水甘油酯和过氧化苯甲酰加入密炼机中，在120℃下熔融接枝30min，即得，其中EVA树脂、甲基丙烯酸缩水甘油酯的质量比为100：10，甲基丙烯酸缩水甘油酯、过氧化苯甲酰的质量比为10：0.5；硅烷偶联剂KH-560改性蒙脱土的制备方法为：将硅烷偶联剂KH-560、乙醇和水按质量比为1：20：2混合均匀，然后加入蒙脱土，在60℃下搅拌反应3h，过滤、干燥，即得，其中蒙脱土与硅烷偶联剂KH-560的质量比为1：0.1。
护套层由下述质量份的原料制成：氯丁橡胶40份、氟硅橡胶5份、氯化聚乙烯30份、炭黑15份、氧化镁10份、氧化锌3份、气相二氧化硅3份、氢氧化镁25份、环氧硬脂酸丁酯3份、硫化剂DCP 5份、硅烷偶联剂KH550 1份、防老剂RD 1份、氯化石蜡0.5份。
实施例3
一种风力发电用耐扭曲软电缆，包括：导体，其中导体由多股软铜线绞合成形而成；包覆在所述导体外部的绝缘层；包覆在所述绝缘层外部的屏蔽层，其中屏蔽层由镀锡铜丝编织而成，编织密度≥85％；和包覆在所述屏蔽层外部的护套层。
绝缘层由下述质量份的原料制成：三元乙丙橡胶100份、EVA-g-GMA 10份、炭黑40份、白炭黑15份、硅烷偶联剂KH-560改性蒙脱土10份、环氧大豆油10份、硫化剂DCP 10份、氧化锌8份、防老剂RD 2份、氯化石蜡2份；EVA-g-GMA的制备方法为：将EVA树脂、甲基丙烯酸缩水甘油酯和过氧化苯甲酰加入密炼机中，在150℃下熔融接枝10min，即得，其中EVA树脂、甲基丙烯酸缩水甘油酯的质量比为100：20，甲基丙烯酸缩水甘油酯、过氧化苯甲酰的质量比为10：1；硅烷偶联剂KH-560改性蒙脱土的制备方法为：将硅烷偶联剂KH-560、乙醇和水按质量比为1：50：5混合均匀，然后加入蒙脱土，在90℃下搅拌反应1h，过滤、干燥，即得，其中蒙脱土与硅烷偶联剂KH-560的质量比为1：0.2。
护套层由下述质量份的原料制成：氯丁橡胶55份、氟硅橡胶10份、氯化聚乙烯40份、炭黑20份、氧化镁15份、氧化锌5份、气相二氧化硅5份、氢氧化镁30份、环氧硬脂酸丁酯5份、硫化剂DCP 8份、硅烷偶联剂KH550 2份、防老剂RD 2份、氯化石蜡1份。
对比例1
对比例1与实施例1的区别仅为：绝缘层的原料不同，其中采用EVA树脂代替EVA-g-GMA。
试验例
对实施例1-3和对比例1的电缆分别进行常温和低温下的扭转试验，试验方法参照：TICW/01-2009附录B，共进行10000次扭转，试验完毕后评价是否通过，评价标准：试样表面无裂纹及扭曲现象，进行2.5U0、15min交流电压试验和导体直流电阻试验，电缆不击穿，评价为通过，否则评价为不通过。评价结果如表1所示：
表1
| 实施例1 | 实施例2 | 实施例3 | 对比例1 | |
| 常温扭转试验 | 通过 | 通过 | 通过 | 不通过 |
| 低温扭转试验 | 通过 | 通过 | 通过 | 不通过 |
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 (8)
1.一种风力发电用耐扭曲软电缆，其特征在于，包括：导体；包覆在所述导体外部的绝缘层；包覆在所述绝缘层外部的屏蔽层；和包覆在所述屏蔽层外部的护套层；
所述绝缘层由下述质量份的原料制成：三元乙丙橡胶90-100份、EVA-g-GMA 5-10份、炭黑30-40份、白炭黑10-15份、硅烷偶联剂KH-560改性蒙脱土5-10份、环氧大豆油5-10份、硫化剂6-10份、氧化锌5-8份、防老剂1-2份、氯化石蜡1-2份；
所述EVA-g-GMA的制备方法为：将EVA树脂、甲基丙烯酸缩水甘油酯和引发剂加入密炼机中，在120-150℃下熔融接枝10-30min，即得；
所述EVA树脂、甲基丙烯酸缩水甘油酯的质量比为100：（10-20）；所述甲基丙烯酸缩水甘油酯、引发剂的质量比为10：（0.5-1）。
2.根据权利要求1所述的风力发电用耐扭曲软电缆，其特征在于，所述引发剂为过氧化二异丙苯、过氧化苯甲酰、过氧化二叔丁基中的至少一种。
3.根据权利要求1所述的风力发电用耐扭曲软电缆，其特征在于，所述硅烷偶联剂KH-560改性蒙脱土是以硅烷偶联剂KH-560对蒙脱土进行表面改性得到，所述蒙脱土与硅烷偶联剂KH-560的质量比为1：（0.1-0.2）。
4.根据权利要求3所述的风力发电用耐扭曲软电缆，其特征在于，所述硅烷偶联剂KH-560改性蒙脱土的制备方法为：将硅烷偶联剂KH-560、乙醇和水按质量比为1：（20-50）：（2-5）混合均匀，然后加入蒙脱土，在60-90℃下搅拌反应1-3h，过滤、干燥，即得。
5.根据权利要求1所述的风力发电用耐扭曲软电缆，其特征在于，所述护套层由下述质量份的原料制成：氯丁橡胶40-55份、氟硅橡胶5-10份、氯化聚乙烯30-40份、炭黑15-20份、氧化镁10-15份、氧化锌3-5份、气相二氧化硅3-5份、无机阻燃剂25-30份、环氧硬脂酸丁酯3-5份、硫化剂5-8份、硅烷偶联剂1-2份、防老剂1-2份、氯化石蜡0.5-1份。
6.根据权利要求5所述的风力发电用耐扭曲软电缆，其特征在于，所述硫化剂为硫化剂DCP、硫化剂DTDM或其组合；所述防老剂为防老剂RD、防老剂IPPD、防老剂6PPD中的至少一种；所述无机阻燃剂为三氧化二锑、氢氧化镁或其组合。
7.根据权利要求1所述的风力发电用耐扭曲软电缆，其特征在于，所述导体由多股软铜线绞合成形而成。
8.根据权利要求1所述的风力发电用耐扭曲软电缆，其特征在于，所述屏蔽层由镀锡铜丝编织而成，编织密度≥85%。
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