CN115612200B - Preparation method of salt spray-resistant and bending-resistant cable of sea surface floating photovoltaic system - Google Patents
Preparation method of salt spray-resistant and bending-resistant cable of sea surface floating photovoltaic system Download PDFInfo
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- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/24—Crosslinking, e.g. vulcanising, of macromolecules
- C08J3/246—Intercrosslinking of at least two polymers
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- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/04—Homopolymers or copolymers of ethene
- C08L23/08—Copolymers of ethene
- C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
- C08L23/0853—Vinylacetate
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- H—ELECTRICITY
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- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
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- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/24—Sheathing; Armouring; Screening; Applying other protective layers by extrusion
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- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
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- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
- H01B7/282—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
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- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/29—Protection against damage caused by extremes of temperature or by flame
- H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame
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- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
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- C08J2323/04—Homopolymers or copolymers of ethene
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- C08J2451/00—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers
- C08J2451/06—Characterised by the use of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
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Abstract
The invention discloses a preparation method of a salt spray resistant and bending resistant cable of a sea surface floating photovoltaic system, which comprises the following steps of S1, extruding an insulating material through a first plastic extruding machine and wrapping the insulating material on a conductor to form an insulating layer; s2, extruding the sheath material through a second extruder, and wrapping the sheath material on the insulating layer to form an outer sheath layer to obtain a semi-finished cable; s3, carrying out irradiation crosslinking on the semi-finished cable by adopting an electron irradiation accelerator, and crosslinking and forming the insulating layer and the sheath layer to obtain the finished cable; the insulating material and/or the sheath material are made of low-smoke halogen-free salt-fog-resistant bending-resistant material. The invention can resist the corrosion of sea water and avoid fatigue cracking of the cable during swinging.
Description
Technical Field
The invention relates to the technical field of cable manufacturing, in particular to a preparation method of a salt spray-resistant and bending-resistant cable of a sea surface floating photovoltaic system.
Background
Solar power generation has been widely used as a high-efficiency clean energy source in various places, including household rooftop photovoltaic power generation, ground photovoltaic power stations, water floating photovoltaic power stations, and the like. Solar power stations inevitably require large space, but in some densely populated areas and countries the land available for construction of solar power stations is scarce or expensive, sometimes both. One approach to this problem is to build a solar power plant on the water surface, or to support the panels on the sea surface by using floating body stands and connect all the panels together.
In the prior art, an insulating layer or a sheath layer applied to a cable of a photovoltaic system generally uses an olefin polymer as a base material, and inorganic crystalline water-containing materials such as aluminum hydroxide, magnesium hydroxide and the like as a flame retardant, and the cable material is prepared by blending, plasticizing and granulating. The existing low-smoke halogen-free flame-retardant polyolefin cable material has the following defects:
1, the conventional halogen-free low-smoke polyolefin flame-retardant insulating layer or sheath layer for the photovoltaic uses ethylene-vinyl acetate copolymer, polyethylene, aluminum hydroxide and magnesium hydroxide, the prepared cable material contains a large amount of inorganic flame retardant, and the conventional surface treatment is carried out by using organosiloxane in a high mixing mode. The treatment method has higher coating efficiency on the surface of the inorganic flame retardant, hydrophilic hydroxyl ions are easily combined with water vapor in the air, the insulation resistance of the material is reduced, and the risk of breakdown or short circuit of the cable is increased.
2, a large amount of polyethylene/ethylene-vinyl acetate copolymer materials are added into a polymer base material in the conventional halogen-free low-smoke polyolefin flame-retardant cable material for the photovoltaic. When the materials are used in an offshore floating photovoltaic system, fatigue is easily generated locally when a cable swings due to blowing of sea wind, so that mechanical performance is deteriorated and even a cracking phenomenon is caused. Due to the two serious defects, the conventional halogen-free low-smoke polyolefin flame-retardant cable material for the photovoltaic has great potential safety hazard when being used in an offshore floating photovoltaic system.
Disclosure of Invention
The invention provides a preparation method of a salt spray-resistant and bending-resistant cable for a sea surface floating photovoltaic system, which can resist corrosion of seawater and avoid fatigue cracking of the cable during swinging.
The technical scheme for solving the technical problems is as follows:
the preparation method of the salt spray-resistant bending-resistant cable of the sea surface floating photovoltaic system comprises the following steps:
s1, extruding an insulating material through a first extruding machine and wrapping the insulating material on a conductor to form an insulating layer;
s2, extruding the sheath material through a second extruder, and wrapping the sheath material on the insulating layer to form an outer sheath layer to obtain a semi-finished cable;
s3, carrying out irradiation crosslinking on the semi-finished cable by adopting an electron irradiation accelerator, and crosslinking and forming the insulating layer and the sheath layer to obtain the finished cable;
the insulating material and/or the sheath material are made of low-smoke halogen-free salt-fog-resistant and bending-resistant materials, and the low-smoke halogen-free salt-fog-resistant and bending-resistant materials are composed of the following raw materials in parts by weight: 90-100 parts of polymer base material, 80-120 parts of radiation grafting modified inorganic flame retardant, 5-10 parts of hexaphenoxy cyclotriphosphazene, 15-30 parts of diethyl aluminum hypophosphite, 15-30 parts of melamine cyanurate, 1-3 parts of nano montmorillonite, 1-3 parts of smoke suppressant ammonium octamolybdate, 3-6 parts of composite antioxidant, 4-7 parts of processing aid and 4-6 parts of environment-friendly color master batch.
Compared with the prior art, the invention has the advantages that:
the invention adopts a gamma or electron beam radiation method to graft hydrophobic vinyl acetate groups on the surfaces of aluminum hydroxide and magnesium hydroxide raw powder, and the hydroxide radical lost by the aluminum hydroxide and the magnesium hydroxide is combined with acetate to form free acetic acid which passes through a height Wen Paichu. After the vinyl acetate group is combined with aluminum/magnesium ions, the vinyl acetate group is a nonpolar group and has stronger hydrophobicity; meanwhile, the vinyl acetate group generates free radical polymerization under the condition of radiation, and Cheng Changlian is formed, so that the hydrophilicity of the inorganic flame retardant is further reduced, and the safety of the product in a salt fog atmosphere can be improved. When the cable is used in the offshore floating photovoltaic system, the waterproof performance of the insulation and the sheath layer is utilized, and a moisture blocking layer or a water blocking layer is not required to be additionally arranged.
And 2. Adding hexaphenoxy cyclotriphosphazene, diethyl aluminum hypophosphite and melamine cyanurate, introducing an acid source and an air source into the material, and matching with a carbon layer formed by an inorganic flame retardant, wherein the flame retardant property of the product can be greatly improved through the barrier effect of the carbon layer.
The polymer base material is characterized in that the polymer base material is provided with a plurality of polymer blocks, wherein the polymer blocks are arranged on the surface of the polymer base material, and the polymer base material is characterized in that an olefin block copolymer is selected in the polymer base material, so that the flexibility and rebound resilience of the polymer base material are improved (when the polymer base material is bent or impacted to produce stress, the stress can lead to silver streaks and/or micro-cavities, namely microscopic occurrence of cracks caused by the fact that the stress overcomes the adhesion between molecular chains, under the action of stress, the molecular chains of the material are straightened from an original group, but are not broken to the extent.
In conclusion, the cable disclosed by the invention has the characteristics of being smooth and smooth in appearance, excellent in flame retardant property, resistant to corrosion of salt fog on the sea, good in long-term water blocking property and resistant to sea wind blowing and swinging.
Drawings
Fig. 1 is a cross-sectional structure diagram of a salt spray-resistant and bending-resistant cable of a sea surface floating photovoltaic system.
Fig. 2 is a schematic diagram of a sheath extrusion apparatus for a sea level floating photovoltaic system cable.
Fig. 3 is a top view of the talc receiving mechanism.
The reference symbols in the drawings:
conductor 1, insulating layer 2, sheath layer 3, pay-off rack 11, second extruder 12, cooling water tank 13, blow dryer 14, spark machine 15, take-up rack 16, talcum powder receiving mechanism 17, input hole 17a, output hole 17b, first protection part 17c, main hopper 18, stirring shaft 19, stirring blade 19a, first sub-hopper 20, through hole 20a, second protection part 20b, second sub-hopper 21, cover plate 22.
Detailed Description
Example 1
As shown in fig. 1 to 3, the preparation method of the salt spray resistant and bending resistant cable of the sea surface floating photovoltaic system comprises the following steps:
s1, extruding and wrapping an insulating material on a conductor 1 through a first extruding machine to form an insulating layer 2, wrapping the insulating layer 2 on the conductor 1 to form a cable core, wherein the insulating material is made of a low-smoke halogen-free salt-fog-resistant bending-resistant material, and extruding and wrapping the low-smoke halogen-free salt-fog-resistant bending-resistant material on a tin-plated copper conductor through the extruding machine to form the insulating layer 2, so that no gap is reserved between the conductor 1 and the insulating layer 2.
In this embodiment, the conductor 1 is a tin-plated stranded copper stranded conductor. The preparation process of the tinning stranded soft copper conductor comprises the following steps: the copper rod is pulled Cheng Luo by a wire drawing machine, a layer of uniform metal tin plating layer is formed on the surface of the copper wire by electroplating or hot tinning the bare copper wire, and the tinned copper wire is stranded into a cable by a stranding machine to form a finished tinned stranded copper stranded conductor.
And S2, extruding the sheath material through a second extruder 12 and wrapping the sheath material on the insulating layer 2 to form an outer sheath layer 3, thereby obtaining the semi-finished cable. The sheath material is made of low-smoke halogen-free salt spray-resistant and bending-resistant materials, and the low-smoke halogen-free salt spray-resistant and bending-resistant materials are extruded on the insulating layer 2 through an extruding machine, so that the insulating layer 2 and the sheath layer 3 are tightly combined together.
The extrusion temperature of the second extruder 12 from barrel one zone to nine zones is respectively: the screw in the second extruder has a pushing pressure of 18-25MPa and an extrusion speed of 10-150m/min, and is 100+ -10 (barrel first zone, feeding zone), 110+ -10 (barrel second zone, feeding zone), 130+ -10 (barrel third zone, plasticizing zone), 140+ -10 (barrel fourth zone, plasticizing zone), 150+ -10 (barrel fifth zone, plasticizing zone), 150+ -10 (barrel sixth zone, plasticizing zone), 160+ -10 (barrel seventh zone, plasticizing zone), 170+ -10 (barrel eighth zone, homogenizing zone), 170+ -10 ℃ (barrel ninth zone, homogenizing zone).
Preferably, after step S1 is completed, the surface of the insulating layer 2 is stuck with talc powder, and then step S2 is performed. When the cable core passes through the second extruder, the sheath layer 3 and the insulating layer 2 are prevented from being adhered together due to the action of high temperature and high pressure.
As shown in fig. 2 to 3, in extruding the sheath layer 3, the structure of the sheath extruding apparatus used is: the device comprises a pay-off rack 11, a second plastic extruding machine 12, a cooling water tank 13, a blow dryer 14, a spark machine 15, a pay-off rack 16 and a talcum powder containing mechanism 17, wherein the following details of each part and the relation of each part in the sheath extruding equipment are described:
as shown in fig. 2 to 3, the pay-off rack 11 is used for releasing the cable core, i.e., the cable core formed of the conductor 1 and the insulation layer 2 is stored in a wound manner on the pay-off rack 11. A second extruder 12 for extruding the jacket material onto the cable core to form a jacket layer 3, the second extruder 12 being located downstream of the pay-off rack 11; the jacket layer 3 is cooled by a cooling water tank 13, and the cooling water tank 13 is located downstream of the second extruder 12. The dryer 14 blows air to the surface of the jacket layer 3, so that the surface of the jacket layer 3 subjected to water cooling is changed into a dry state in a wet state, and the dryer 14 is positioned downstream of the cooling water tank 13. The sparker 15 is used to test whether the jacket layer 3 will break down under the corresponding electric field, the sparker 15 being located downstream of the dryer 14. After extrusion of the sheath layer 3 on the cable core, the cable is obtained, wound up by a take-up reel 16, the take-up reel 16 being located downstream of the sparking machine 15.
As shown in fig. 2 to 3, the talcum powder storage mechanism 17 is filled with talcum powder, the talcum powder storage mechanism 17 is located between the pay-off rack 11 and the second plastic extruding machine 12, and the talcum powder storage mechanism 17 is provided with an input hole 17a and an output hole 17b for a cable core to pass through. The cable core passes through the input hole 17a and the output hole 17b in sequence, and when the cable core passes through the talcum powder containing mechanism 17, the talcum powder is passed through simultaneously, so that the talcum powder is attached to the surface of the insulating layer 2, and when the second plastic extruding machine 12 extrudes the sheath layer 3 on the cable core, the sheath layer 3 and the insulating layer 2 can be prevented from being adhered together due to the action of high temperature and high pressure of the second plastic extruding machine 12.
As shown in fig. 2 to 3, the talc powder accommodating mechanism 17 further includes a first protection member 17c for isolating the cable core from the wall surface of the input hole 17a, and the first protection member 17c is annular and cooperates with the input hole 17 a. Through the isolation effect of the first protection part 17c, the cable core is prevented from rubbing with the input hole 17a when passing through the input hole 17a, and the hole wall of the input hole 17a is prevented from scraping the insulating layer 2, so that the roundness of the insulating layer 2 is kept, and the first protection part 17c in the embodiment preferably adopts sponge which has the characteristic of softness.
As shown in fig. 2 to 3, the talc powder receiving mechanism 17 includes a main hopper 18, a stirring shaft 19, stirring blades 19a, and a driver, the main hopper 18 is used for receiving talc powder, and the input hole 17a and the output hole 17b are respectively provided at both ends of the main hopper 18; the stirring shaft 19 is located at the middle lower part in the main hopper 18, two ends of the stirring shaft 19 are respectively rotatably supported on the main hopper 18, the stirring blades 19a form a stirring state when working, the stirring blades 19a are fixed with the stirring shaft 19, the stirring shaft 19 is driven to rotate by a driver (not shown in the figure), and the driver is connected with the stirring shaft 19. The driver may be composed of a motor, a speed reducer, and a belt transmission mechanism, or the driver may be composed of a motor, a speed reducer, and a gear transmission mechanism.
As shown in fig. 2 to 3, the stirring shaft 19 is driven to rotate by the driver, so that the stirring blade 19a rotates, and the stirring blade 19a causes the talcum powder to be in a turned state, which can cause more talcum powder to be attached to the surface of the insulating layer 2, and at the same time, the talcum powder attached to the surface of the insulating layer 2 can be more uniform.
As shown in fig. 2 to 3, the talc powder receiving mechanism 17 further includes a first sub-hopper 20 for receiving the powder material overflowed from the input hole 17a, the first sub-hopper 20 being provided on a side of the main hopper 18 where the input hole 17a is provided, and since the talc powder in the main hopper 18 is in a tumbling state by the driving of the stirring blade 19a, it is possible to cause the talc powder to overflow to the outside of the main hopper 18 through the input hole 17a, so that in the present embodiment, the talc powder overflowed from the input hole 17a is received by the first sub-hopper 20, thereby avoiding contamination of the working environment.
As shown in fig. 2 to 3, in the present embodiment, the height of the opening of the first sub-hopper 20 is equal to that of the opening of the main hopper 18, so that the first sub-hopper 20 is provided with a through hole 20a through which the cable core passes, and the talc powder accommodating mechanism 17 further includes a second protection member 20b for isolating the cable core from the wall surface of the through hole 20a, and the second protection member 20b is annular and is engaged with the through hole 20 a.
As shown in fig. 2 to 3, by the isolation effect of the second protection member 20b, friction between the cable core and the wall of the through hole 20a is avoided when the cable core passes through the through hole 20a, and scraping of the wall of the through hole 20a against the insulating layer 2 is prevented, so that the roundness of the insulating layer 2 is maintained, and in this embodiment, the second protection member 20b preferably adopts a sponge.
As shown in fig. 2 to 3, the talc powder receiving mechanism 17 further includes a second sub-hopper 21 for receiving the powder material overflowed from the output hole 17b, the second sub-hopper 21 is provided on the other side of the main hopper 18 where the output hole 17b is provided, and since the insulating layer with talc powder attached to the surface cannot contact with a protective member such as a sponge or the wall surface of the output hole 17b, in this embodiment, the opening of the second sub-hopper 22 is located below the output hole 17b on the one hand, and the inner hole of the output hole 17b is provided to be at least 2 times larger than the outer diameter of the cable core on the other hand, so as to avoid scraping of the winding core with the wall surface of the output hole 17b due to shaking or the like.
As shown in fig. 2 to 3, the talcum powder is in a stirring state under the driving of the stirring blade 20, and because the talcum powder is in a powder state and is easy to scatter outside the main hopper 18 in the stirring process, and pollution is formed to the working environment, the talcum powder storage mechanism 17 in the embodiment further comprises a cover plate 22, one end of the cover plate 22 is hinged with the main hopper 18, and the opening of the main hopper 18 is shielded through the cover plate 22, so that the talcum powder is prevented from scattering everywhere.
S3, carrying out irradiation crosslinking on the semi-finished cable by adopting an electron irradiation accelerator, and crosslinking and forming the insulating layer and the sheath layer to obtain the finished cable. In step S3, the cable is irradiated with an electron accelerator having an energy of 1.5 to 2.5MeV, a beam current of 10 to 40mA, and a scan width of 120 cm.
The insulating layer 2 and the sheath layer 3 are made of low-smoke halogen-free salt-fog-resistant bending-resistant materials, and in the embodiment, the low-smoke halogen-free salt-fog-resistant bending-resistant materials are composed of the following raw materials in parts by weight: 100 parts of polymer base material, 100 parts of radiation grafting modified inorganic flame retardant, 7 parts of hexaphenoxy cyclotriphosphazene, 20 parts of diethyl aluminum hypophosphite, 20 parts of melamine cyanurate, 2 parts of nano montmorillonite, 1 part of smoke suppressant ammonium octamolybdate, 4 parts of composite antioxidant, 4 parts of processing aid and 4 parts of environment-friendly color master batch.
The polymer base material consists of the following raw materials in parts by weight: 10 parts of a chemical compatilizer for grafting maleic anhydride, 20 parts of an olefin block copolymer, 55 parts of an ethylene-vinyl acetate copolymer with a VA content of 20%, 5 parts of an ethylene-octene copolymer and 5 parts of an ethylene-methyl methacrylate copolymer with a MA content of 22%; wherein the chemical compatilizer is a composition formed by LDPE-g-MAH, LLDPE-g-MAH and POE-g-MAH.
The preparation process of the radiation grafting modified inorganic flame retardant comprises the following steps: 50kg of a mixture of aluminum hydroxide and magnesium hydroxide is weighed, wherein the weight ratio of the aluminum hydroxide to the magnesium hydroxide is 2:1. 1kg of vinyl acetate is dissolved in 30L of ethanol, then aluminum hydroxide and magnesium hydroxide are mixed uniformly with the vinyl acetate dissolved in the ethanol, the mixture is placed into a vacuum sealing bag for vacuum pumping and sealing, and then gamma or electron beam radiation is carried out to enable groups in the vinyl acetate to be grafted on the surfaces of the aluminum hydroxide and the magnesium hydroxide. The irradiation absorption dose is 35kGy, and after the irradiation is finished, the sample is dried and then is weighed to calculate the grafting rate, wherein the grafting rate is 1%.
The compound antioxidant comprises: 2 parts of a primary antioxidant and 1 part of a secondary antioxidant, wherein the primary antioxidant is a composition consisting of: pentaerythritol tetrakis [ beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate (1010), octadecyl beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate (1076), N '-bis [ beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionyl ] hydrazine (1024), bis (2-methyl-5-tert-butyl-4-hydroxyphenyl) sulfide, 4' -thiobis (6-tert-butyl-3-methylphenol) (300); the auxiliary antioxidants are didodecyl thiodipropionate and dioctadecyl thiodipropionate.
The processing aid consists of a crosslinking sensitizer and a lubricant, wherein the weight part of the crosslinking sensitizer is 1 part, and the weight part of the lubricant is 5 parts. The crosslinking sensitizer comprises trimethylolpropane trimethacrylate and triallyl isocyanurate. The lubricant consists of polyethylene wax, zinc stearate, calcium stearate, silicone master batch and ethylene bis-stearamide.
The preparation process of the low-smoke halogen-free salt-fog-resistant bending-resistant material comprises the following steps of: weighing a polymer base material, an inorganic flame retardant, hexaphenoxy cyclotriphosphazene, diethyl aluminum hypophosphite, melamine cyanurate, nano montmorillonite, an smoke suppressant ammonium octamolybdate, a composite antioxidant, a processing aid and environment-friendly color master batch according to parts, putting the materials into a pressurized internal mixer, controlling the pressure of the internal mixer to be 2.53MPa, and mixing the materials in the internal mixer to 175 ℃ to ensure that the components are uniformly mixed to form a mixed soft jelly; and (3) putting the obtained mixed soft jelly into a double-screw extruder for extrusion to obtain a granular low-smoke halogen-free salt-fog-resistant bending-resistant material, wherein the length of the granular low-smoke halogen-free salt-fog-resistant bending-resistant material is 0.5cm, and the diameter of the bottom surface is 0.25cm. And (3) air-cooling and packaging the granular low-smoke halogen-free salt-fog-resistant bending-resistant material.
The temperature of the twin-screw extruder is: the vacuum pump is set at 0.1 to 0.2ATM for the first zone 130 to 145 ℃ (charging zone), the second zone 130 to 145 ℃ (charging zone), the third zone 130 to 145 ℃ (plasticizing zone), the fourth zone 130 to 145 ℃ (plasticizing zone), the fifth zone 130 to 145 ℃ (plasticizing zone), the sixth zone 130 to 145 ℃ (plasticizing zone), the seventh zone 130 to 145 ℃ (plasticizing zone), the eighth zone 130 to 145 ℃ (homogenizing zone), the ninth zone 130 to 145 ℃ (homogenizing zone), die 140 to 155 ℃.
In this example, the twin screw extruder temperature is: the vacuum pump pressure was set at 0.15ATM for the first zone 130 ℃ (charging section), the second zone 132 ℃ (charging section), the third zone 134 ℃ (plasticizing section), the fourth zone 136 ℃ (plasticizing section), the fifth zone 138 ℃ (plasticizing section), the sixth zone 140 ℃ (plasticizing section), the seventh zone 142 ℃ (plasticizing section), the eighth zone 144 ℃ (homogenizing section), the ninth zone 145 ℃ (homogenizing section), and the die 150 ℃.
The cable made of the insulating layer 2 and the sheath layer 3 of the low smoke zero halogen salt spray resistant bending resistant material in example 1 was subjected to related test experiments with the existing photovoltaic low smoke zero halogen flame retardant cable materials sold in the market, and the detection and comparison results are shown in table 1 below.
Table 1 test results of test experiments
(1) As shown in Table 1, the comparative index (1) in Table 1 shows that the volume resistivity index of the commercial photovoltaic low-smoke halogen-free flame-retardant cable material is significantly lower than that of example 1.
(2) As can be seen from the comparative indexes (1) and (2) in table 1, the volume resistivity of 20 ℃ before and after immersing in NaCl solution was measured, and the values of the product of example 1 before immersing were: 1.9X10 15 The values before soaking for the product of example 1 are: 1.0X10 15 The values before soaking for the commercial product are: 1.3X10 14 The values before soaking for the commercial product are: 3.2X10 8 As can be seen by comparison, the volume resistivity of the product of example 1 is slightly reduced at 20 ℃ after the product is soaked in NaCl solution, while the product of example 1 can still maintain the insulation performance meeting the photovoltaic standard requirement after the product is soaked in sodium chloride solution, so that the long-term stable operation of the cable can be ensured. And after the commercial product is soaked in NaCl solution, the volume resistivity at 20 ℃ is exponentially reduced (by 6 orders of magnitude), so that great hidden danger is brought to the safe operation of the cable, and the cable is possibly overheated, broken down and fired, thereby causing safety accidents.
(3) As can be seen from the comparison index (3) in table 1, after 10000 times of swinging, the appearance of the cable made of the commercial photovoltaic low-smoke halogen-free flame-retardant cable material has obvious stress whitening phenomenon, and the appearance of the product of the embodiment is normal; after 20000 times of swinging, the breakdown phenomenon occurs when a cable made of a commercial photovoltaic low-smoke halogen-free flame-retardant cable material passes through a high-voltage spark machine, and no alarm occurs when the cable made of the product of the embodiment passes through the high-voltage spark machine, which indicates that the product of the embodiment has excellent flexibility, rebound resilience and bending resistance, and under the condition of swinging and swinging, the phenomenon of cracking and breakage caused by material fatigue does not occur, so that the cable can be ensured to be safely and effectively applied to a sea surface floating photovoltaic system.
(4) From the comparative index (4) in table 1, it can be seen that the product of example 1 can meet the waterproof requirement for water projects after long-term soaking (90±2 ℃ x 2016 h) by insulating and breakdown-free, while the cable prepared from the commercial photovoltaic low-smoke halogen-free flame-retardant cable material can not meet the waterproof requirement for water projects after long-term soaking by insulating and breakdown-free.
(5) As can be seen from the comparative index (5) in Table 1, the product of example 1 can pass the salt spray test of IEC 60068-2-52, and the cable made of the commercial photovoltaic low-smoke halogen-free flame-retardant cable material can not achieve the performance.
Example 2
Example 2 differs from example 1 in the ratio of the low smoke zero halogen salt spray resistant and bending resistant materials, specifically as follows:
in the embodiment, the low-smoke halogen-free salt spray-resistant bending-resistant material comprises the following raw materials in parts by weight: 98 parts of polymer base material, 105 parts of radiation grafting modified inorganic flame retardant, 6 parts of hexaphenoxy cyclotriphosphazene, 23 parts of diethyl aluminum hypophosphite, 25 parts of melamine cyanurate, 1 part of nano montmorillonite, 2 parts of smoke suppressant ammonium octamolybdate, 5 parts of composite antioxidant, 5 parts of processing aid and 5 parts of environment-friendly color master batch.
The polymer base material consists of the following raw materials in parts by weight: 12 parts of a chemical compatilizer grafted with maleic anhydride, 22 parts of an olefin block copolymer, 52 parts of an ethylene-vinyl acetate copolymer with a VA content of 25%, 7 parts of an ethylene-octene copolymer and 4 parts of an ethylene-methyl methacrylate copolymer with a MA content of 20%; wherein the chemical compatilizer is LDPE-g-MAH.
The preparation process of the radiation grafting modified inorganic flame retardant comprises the following steps: 50kg of a mixture of aluminum hydroxide and magnesium hydroxide is weighed, and the weight ratio of the aluminum hydroxide to the magnesium hydroxide is 2:1. 1.5kg of vinyl acetate is dissolved in 35L of acetone, then aluminum hydroxide and magnesium hydroxide are evenly mixed with the vinyl acetate dissolved in the acetone, the mixture is placed into a vacuum sealing bag for vacuum pumping and sealing, and then gamma or electron beam radiation is carried out, so that groups in the vinyl acetate are grafted on the surfaces of the aluminum hydroxide and the magnesium hydroxide. The irradiation absorption dose is 45kGy, and after the irradiation is finished, the sample is dried and then is weighed to calculate the grafting rate, wherein the grafting rate is 1.5%.
The compound antioxidant comprises: 3 parts of primary antioxidant and 2 parts of secondary antioxidant, wherein the primary antioxidant is a composition consisting of the following substances: pentaerythritol tetrakis [ beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate (1010), octadecyl beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate (1076), N '-bis [ beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionyl ] hydrazine (1024), bis (2-methyl-5-tert-butyl-4-hydroxyphenyl) sulfide, 4' -thiobis (6-tert-butyl-3-methylphenol) (300); the auxiliary antioxidants are didodecyl thiodipropionate and dioctadecyl thiodipropionate.
The processing aid consists of a crosslinking sensitizer and a lubricant, wherein the weight part of the crosslinking sensitizer is 1.5 parts, and the weight part of the lubricant is 4.5 parts. The crosslinking sensitizer comprises trimethylolpropane trimethacrylate and triallyl isocyanurate. The lubricant consists of polyethylene wax, zinc stearate, calcium stearate, silicone master batch and ethylene bis-stearamide.
Weighing a polymer base material, an inorganic flame retardant, hexaphenoxy cyclotriphosphazene, diethyl aluminum hypophosphite, melamine cyanurate, nano montmorillonite, an smoke suppressant ammonium octamolybdate, a composite antioxidant, a processing aid and environment-friendly color master batch according to parts, putting the materials into a pressurized internal mixer, controlling the pressure of the internal mixer to be 3MPa, and mixing the materials in the internal mixer to 172 ℃ to ensure that all the components are uniformly mixed to form a mixed soft jelly; and (3) putting the obtained mixed soft jelly into a double-screw extruder for extrusion to obtain a granular low-smoke halogen-free salt-fog-resistant bending-resistant material, wherein the length of the granular low-smoke halogen-free salt-fog-resistant bending-resistant material is 0.5cm, and the diameter of the bottom surface is 0.25cm. And (3) air-cooling and packaging the granular low-smoke halogen-free salt-fog-resistant bending-resistant material.
In this example, the twin screw extruder temperature is: first zone 131 ℃ (charging zone), second zone 133 ℃ (charging zone), third zone 134 ℃ (plasticizing zone), fourth zone 135 ℃ (plasticizing zone), fifth zone 137 ℃ (plasticizing zone), sixth zone 149 ℃ (plasticizing zone), seventh zone 141 ℃ (plasticizing zone), eighth zone 143 ℃ (homogenizing zone), ninth zone 145 ℃ (homogenizing zone), die 148 ℃, set vacuum pump pressure 0.2ATM.
Finally, it should be noted that: the above embodiments are merely preferred embodiments of the present invention for illustrating the technical solution of the present invention, but not for limiting the scope of the present invention; although the invention has been described in detail with reference to the foregoing embodiments, it will be appreciated by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the corresponding technical solutions.
Claims (9)
1. The preparation method of the salt spray-resistant bending-resistant cable of the sea surface floating photovoltaic system is characterized by comprising the following steps of:
s1, extruding an insulating material through a first extruding machine and wrapping the insulating material on a conductor to form an insulating layer;
s2, extruding the sheath material through a second extruder, and wrapping the sheath material on the insulating layer to form an outer sheath layer to obtain a semi-finished cable;
s3, carrying out irradiation crosslinking on the semi-finished cable by adopting an electron irradiation accelerator, and crosslinking and forming the insulating layer and the sheath layer to obtain the finished cable;
the insulating material and/or the sheath material are made of low-smoke halogen-free salt-fog-resistant and bending-resistant materials, and the low-smoke halogen-free salt-fog-resistant and bending-resistant materials are composed of the following raw materials in parts by weight: 90-100 parts of polymer base material, 80-120 parts of radiation grafting modified inorganic flame retardant, 5-10 parts of hexaphenoxy cyclotriphosphazene, 15-30 parts of diethyl aluminum hypophosphite, 15-30 parts of melamine cyanurate, 1-3 parts of nano montmorillonite, 1-3 parts of smoke suppressant ammonium octamolybdate, 3-6 parts of composite antioxidant, 4-7 parts of processing aid and 4-6 parts of environment-friendly color master batch;
the polymer base material consists of the following raw materials in parts by weight:
5-15 parts of a chemical compatilizer for grafting maleic anhydride, 15-30 parts of an olefin block copolymer, 50-65 parts of an ethylene-vinyl acetate copolymer with the VA content of 18-28%, 5-15 parts of an ethylene-octene copolymer and 0-10 parts of an ethylene-methyl methacrylate copolymer with the MA content of 18-28%;
wherein the chemical compatilizer is one or more of LDPE-g-MAH, LLDPE-g-MAH and POE-g-MAH;
the preparation process of the radiation grafting modified inorganic flame retardant comprises the following steps: 50kg of a mixture of aluminum hydroxide and magnesium hydroxide is weighed, wherein the weight ratio of the aluminum hydroxide to the magnesium hydroxide is 2:1, 1kg of vinyl acetate is dissolved into 30L of ethanol, then aluminum hydroxide and magnesium hydroxide are evenly mixed with the vinyl acetate dissolved in the ethanol, the mixture is placed into a vacuum sealing bag for vacuum pumping and sealing, then gamma or electron beam radiation is carried out, so that groups in the vinyl acetate are grafted onto the surfaces of the aluminum hydroxide and the magnesium hydroxide, the radiation absorption dose is 35kGy, and after the radiation is finished, a sample is dried, and then the grafting rate is calculated by weighing, wherein the grafting rate is 1%.
2. The method for preparing the salt spray resistant and bending resistant cable of the sea surface floating photovoltaic system according to claim 1, wherein the preparation process of the inorganic flame retardant is as follows:
weighing 50kg of mixture of aluminum hydroxide and magnesium hydroxide, dissolving 0.5-2kg of vinyl acetate into 1-50L of ethanol or acetone, uniformly blending the aluminum hydroxide and the magnesium hydroxide with the vinyl acetate dissolved in the ethanol or the acetone, placing into a vacuum sealing bag for vacuum pumping and sealing, and then carrying out gamma or electron beam radiation to enable groups in the vinyl acetate to be grafted onto the aluminum hydroxide and the magnesium hydroxide.
3. The method for preparing the salt spray resistant and bending resistant cable of the sea surface floating photovoltaic system according to claim 2, wherein the weight ratio of the aluminum hydroxide to the magnesium hydroxide is 2:1.
4. the preparation method of the salt spray and bending resistant cable of the sea surface floating photovoltaic system, according to claim 1, is characterized in that the preparation process of the low-smoke halogen-free salt spray and bending resistant material is as follows:
weighing a polymer base material, an inorganic flame retardant, hexaphenoxy cyclotriphosphazene, diethyl aluminum hypophosphite, melamine cyanurate, nano montmorillonite, smoke suppressant ammonium octamolybdate, a composite antioxidant, a processing aid and environment-friendly color master batch according to parts, putting into a pressurized internal mixer, controlling the pressure of the internal mixer to be 2.5-3MPa, and mixing in the internal mixer to 160-180 ℃ to uniformly mix various components to form a mixed soft jelly; and (3) putting the obtained mixed soft jelly into a double-screw extruder for extrusion to obtain the granular low-smoke halogen-free salt-fog-resistant bending-resistant material.
5. The method for preparing the salt spray resistant and bending resistant cable of the sea surface floating photovoltaic system according to claim 1, wherein the composite antioxidant comprises the following steps: 2-4 parts of primary antioxidant and 1-3 parts of auxiliary antioxidant, wherein,
the main antioxidant is a composition consisting of the following substances: pentaerythritol tetrakis [ beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate (1010), octadecyl beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionate (1076), N '-bis [ beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionyl ] hydrazine (1024), bis (2-methyl-5-tert-butyl-4-hydroxyphenyl) sulfide, 4' -thiobis (6-tert-butyl-3-methylphenol) (300);
the auxiliary antioxidant is didodecyl thiodipropionate and/or dioctadecyl thiodipropionate.
6. The preparation method of the salt spray resistant and bending resistant cable of the sea surface floating photovoltaic system, which is characterized in that the processing aid consists of 1-2 parts by weight of a crosslinking sensitizer and 4-6 parts by weight of a lubricant.
7. The method for preparing the salt spray-resistant and bending-resistant cable of the sea surface floating photovoltaic system according to claim 6, wherein the crosslinking sensitizer comprises trimethylolpropane trimethacrylate and/or triallyl isocyanurate.
8. The method for preparing the salt spray-resistant and bending-resistant cable of the sea surface floating photovoltaic system according to claim 1, wherein in the step S3, the cable is irradiated by using an electron accelerator with energy of 1.5 to 2.5MeV, beam current of 10 to 40mA and scanning width of 120 cm.
9. The method for preparing a salt spray resistant and bending resistant cable for a sea surface floating photovoltaic system according to any one of claims 1 to 8, wherein after step S1 is completed, the surface of the insulating layer is stuck with talcum powder, and then step S2 is performed.
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