CN116120658A - 一种耐霉菌型无卤橡胶护套材料及包含其的电缆桥电缆 - Google Patents
一种耐霉菌型无卤橡胶护套材料及包含其的电缆桥电缆 Download PDFInfo
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Abstract
本发明提供一种耐霉菌型无卤橡胶护套材料及包含其的电缆桥电缆,所述耐霉菌型无卤橡胶护套材料以EVA和POE作为基材,添加阻燃剂、白炭黑、防霉剂、微晶蜡、炭黑、硫化剂、硬脂酸和增塑剂,综合上述多种材料的特点,取长补短,具有优异的耐老化性能、耐高低温性能、耐盐雾腐蚀性能、耐油性能和耐霉菌等性能,使得采用其作为橡胶护套层的材料制成的电缆桥电缆不仅具有无卤低烟的特性,燃烧时无有害卤气散发,确保当海上风机遇到突发火灾时,保证人身安全,同时其还具有耐霉菌的特性,在湿热的恶劣条件下,能有效避免霉菌的滋长,保护电缆不受有害物质的侵害。
Description
技术领域
本发明属于电缆材料技术领域,具体涉及一种耐霉菌型无卤橡胶护套材料及包含其的电缆桥电缆。
背景技术
近年来,随着海上风电技术快速发展,海上风电机组单机容量由早期的3~4MW向8~10MW等大容量机型升级,未来单机容量还将进一步提升,可达到15MW以上。目前,国内外的风场集电线路主要采用35kV电压系统,但随着单机容量增大,风场集电线路系统电压将会提升至66kV等级,相较于35kV电压系统可以减少阵列输电回路数,从而降低海上升压站接线复杂度,甚至减少海上升压站的数量,能降低业主的投资和运维成本。为了能够保证风机电压系统与风电场集电线路电压系统匹配,风机整机商主要采用在风机底部变压器升压至66kV后再将电能传输出去,因此提出在变压器与环网柜之间采用单芯66kV高压电缆桥的固定连接方案。
常规的风能高压电缆一般采用含有卤素的氯丁橡皮护套电缆。CN105218905A公开了一种氯丁橡胶电缆护套材料的制备方法,包括:首先将氯丁橡胶、氯化聚乙烯及乙丁橡胶为基料进行一次塑炼,冷却至室温进行二次塑炼;向得到物料中加入聚乙烯蜡、环氧大豆油、抗氧剂、硬脂酸、半补强炭黑、有机改性膨润土、纳米二氧化硅、笼形八苯基硅倍半氧烷、癸二酸二辛酯置于密炼机中混炼均匀后下片冷却;向制备的物料加入氧化镁、叔丁基异丙苯基过氧化物、促进剂M及促进剂TMTD混炼均匀后排料;薄通2~4次,压延成型,硫化,出料冷却得到氯丁橡胶电缆护套材料;上述氯丁橡胶电缆护套材料的制备方法,具有良好的耐热、阻燃性能,硬度高,压缩变形小,制备成本低,工艺简单。但是,氯丁橡皮护套电缆无法满足无卤和低烟的性能要求,随着风电行业的不断发展,人们对无卤低烟型的电缆的需求越来越多,另外风能高压电缆一般应用在远离海岸的大功率风机中,海上环境恶劣,盐雾湿气大,电缆运行期间容易滋生霉菌等有害物质。
因此,期待开发一种具有耐老化、耐油、耐盐雾以及耐霉菌的耐霉菌型无卤橡胶护套材料。
发明内容
针对现有技术的不足,本发明的目的在于提供一种耐霉菌型无卤橡胶护套材料及包含其的电缆桥电缆,所述耐霉菌型无卤橡胶护套材料以EVA和POE作为基材,添加阻燃剂、白炭黑、防霉剂、微晶蜡、炭黑、硫化剂、硬脂酸和增塑剂,综合上述多种材料的特点,取长补短,具有优异的耐老化性能、耐高低温性能、耐盐雾腐蚀性能、耐油性能和耐霉菌等性能。
为达到此发明目的,本发明采用以下技术方案:
第一方面,本发明提供一种耐霉菌型无卤橡胶护套材料,所述耐霉菌型无卤橡胶护套材料按照重量份包括如下组分:
其中,所述POE可以为6重量份、8重量份、10重量份、12重量份或14重量份等。
所述阻燃剂可以为85重量份、90重量份、95重量份、100重量份、105重量份、110重量份或115重量份等。
所述白炭黑可以为17重量份、19重量份、21重量份、23重量份或25重量份等。
所述防霉剂可以为8.5重量份、9重量份、9.5重量份、10重量份、10.5重量份、11重量份或11.5重量份等。
所述微晶蜡可以为3.2重量份、3.4重量份、3.6重量份、3.8重量份、4重量份、4.2重量份、4.4重量份、4.6重量份或4.8重量份等。
所述炭黑可以为2.2重量份、2.4重量份、2.6重量份、2.8重量份、3重量份、3.2重量份、3.4重量份、3.6重量份或3.8重量份等。
所述硫化剂可以为4.5重量份、5重量份、5.5重量份、6重量份、6.5重量份、7重量份或7.5重量份等。
所述硬脂酸可以为1.3重量份、1.6重量份、1.8重量份、2.2重量份、2.5重量份或2.8重量份等。
所述增塑剂可以为3.2重量份、3.4重量份、3.6重量份、3.8重量份、4重量份、4.2重量份、4.4重量份、4.6重量份或4.8重量份等。
本发明提供的耐霉菌型无卤橡胶护套材料以EVA和POE搭配作为基材,配合添加阻燃剂、白炭黑、防霉剂、微晶蜡、炭黑、硫化剂、硬脂酸和增塑剂,综合多种材料的性能,取长补短,使得到的耐霉菌型无卤橡胶护套材料具有优异的耐老化、耐高低温、高强度、耐盐雾腐蚀、耐油、耐霉菌等性能。
优选地,所述阻燃剂包括改性氢氧化镁和改性氢氧化铝的组合。
优选地,所述耐霉菌型无卤橡胶护套材料中改性氢氧化镁的含量为70~90重量份,例如72重量份、74重量份、76重量份、78重量份、80重量份、82重量份、84重量份、86重量份或88重量份等。
优选地,所述耐霉菌型无卤橡胶护套材料中改性氢氧化铝的含量为10~30重量份,例如12重量份、14重量份、16重量份、18重量份、20重量份、22重量份、24重量份、26重量份或28重量份等。
优选地,所述硫化剂包括过氧化二异丙苯(DCP)和三烯丙基异三聚氰酸酯(TAIC)。
优选地,所述耐霉菌型无卤橡胶护套材料中过氧化二异丙苯的含量为3~5重量份,例如3.2重量份、3.4重量份、3.6重量份、3.8重量份、4重量份、4.2重量份、4.4重量份、4.6重量份或4.8重量份等。
优选地,所述耐霉菌型无卤橡胶护套材料中三烯丙基异三聚氰酸酯的含量为1~3重量份,例如1.3重量份、1.6重量份、1.9重量份、2.2重量份、2.5重量份或2.8重量份等。
优选地,所述增塑剂包括癸二酸二辛酯(DOS)。
优选地,所述耐霉菌型无卤橡胶护套材料中还包括防老剂和/或偶联剂。
优选地,所述耐霉菌型无卤橡胶护套材料中防老剂的含量为2~4重量份,例如2.2重量份、2.4重量份、2.6重量份、2.8重量份、3重量份、3.2重量份、3.4重量份、3.6重量份或3.8重量份等。
优选地,所述耐霉菌型无卤橡胶护套材料中偶联剂的含量为0.5~1.5重量份,例如0.6重量份、0.7重量份、0.8重量份、0.9重量份、1重量份、1.1重量份、1.2重量份、1.3重量份或1.4重量份等。
第二方面,本发明提供一种如第一方面所述耐霉菌型无卤橡胶护套材料的制备方法,所述制备方法包括如下步骤:
(1)将EVA和POE进行混炼,得到第一混炼胶;
(2)将步骤(1)得到的混炼胶、阻燃剂、白炭黑、防霉剂、微晶蜡、炭黑、硬脂酸、增塑剂、任选地防老剂和任选地偶联剂进行混炼,得到第二混炼胶;
(3)将步骤(1)得到的混合物和硫化剂进行混炼,得到所述耐霉菌型无卤橡胶护套材料。
优选地,步骤(1)所述混炼的时间为1~2min,例如1.2min、1.4min、1.6min或1.8min等。
优选地,步骤(1)所述混炼的温度为105~115℃,例如107℃、109℃、111℃、113℃或115℃等。
优选地,步骤(2)所述混炼的时间为4~5min,例如4.2min、4.4min、4.6min或4.8min等。
优选地,步骤(2)所述混炼的温度为105~115℃,例如107℃、109℃、111℃、113℃或115℃等。
优选地,步骤(3)所述混炼的时间为0.5~1min,例如0.55min、0.6min、0.65min、0.7min、0.75min、0.8min、0.85min、0.9min或0.95min等。
优选地,步骤(3)所述混炼的温度为105~115℃,例如107℃、109℃、111℃、113℃或115℃等。
第二方面,本发明提供一种电缆桥电缆,所述电缆桥电缆包括中心导体,所述中心导体外依次包覆有半导电尼龙带层、导体屏蔽层、绝缘层、绝缘屏蔽层、第一半导电阻水带层、镀锡铜丝疏绕屏蔽层、第二半导电阻水带层和橡胶护套层;
所述橡胶护套层的原料为如第一方面所述的耐霉菌型无卤橡胶护套材料。
首先,本发明提供的电缆的橡胶护套层的材料采用的是本发明第一方面所提供的耐霉菌型无卤橡胶护套材料,相比氯丁橡胶等含有卤素的材料而言,其不仅具有无卤低烟的特性,燃烧时无有害卤气散发,同时透光率≥60%,确保当海上风机遇到突发火灾时,保证人身安全;同时其还具有耐霉菌的特性,在湿热的恶劣条件下,能有效避免霉菌的滋长,保护电缆不受有害物质的侵害;
其次,作为大功率风机专用的电缆桥电缆,其金属屏蔽层采用镀锡铜单丝螺旋式疏绕的排列方式,可增强电缆的柔软弯曲性能,也可保护电缆因短路所具备的金属屏蔽接地故障载流能力,其结构优于普通的铜丝编织金属屏蔽,同时在金属屏蔽层的下方和上方分别应用一层半导电阻水带,可有效隔绝潮气进入电缆中,保证电缆的电气安全性。
优选地,所述中心导体为绞合镀锡软铜导体,镀锡软铜导体:采用GB/T3956标准规定的第5种圆形绞合镀锡软铜导体,导体表面光洁、无损伤绝缘的毛刺、锐边以及凸起或断裂的单线。
优选地,所述半导电尼龙带采用重叠绕包的形式包覆在中心导体上。
优选地,所述导体屏蔽层的材料采用66kV超洁净半导电内屏料,性能符合IEC60840标准的规定。
优选地,所述绝缘层的材料采用66kV超洁净EPR绝缘料,性能符合IEC60840标准的规定。
优选地,所述绝缘屏蔽层的材料采用66kV超洁净不可剥离半导电外屏料,性能符合IEC 60840标准的规定。
第四方面,本发明提供一种如第三方面所述的电缆在大功率风机塔中的应用。
相对于现有技术,本发明具有以下有益效果:
本发明提供的耐霉菌型无卤橡胶护套材料以EVA和POE搭配作为基材,配合添加阻燃剂、白炭黑、防霉剂、微晶蜡、炭黑、硫化剂、硬脂酸和增塑剂,综合多种材料的性能,取长补短,使得到的耐霉菌型无卤橡胶护套材料具有优异的耐老化、耐高低温、高强度、耐盐雾腐蚀、耐油、耐霉菌等性能;采用其作为橡胶护套层的电缆桥电缆不仅具有无卤低烟的特性,燃烧时无有害卤气散发,同时透光率≥60%,确保当海上风机遇到突发火灾时,保证人身安全;同时其还具有耐霉菌的特性,在湿热的恶劣条件下,能有效避免霉菌的滋长,保护电缆不受有害物质的侵害。
附图说明
图1为本发明提供的电缆桥电缆的剖面结构示意图,其中,1-中心导体,2-半导电尼龙带层,3-导体屏蔽层,4-绝缘层,5-绝缘屏蔽层,6-第一半导电阻水带层,7-镀锡铜丝疏绕屏蔽层,8-第二半导电阻水带层和9-橡胶护套层。
具体实施方式
下面通过具体实施方式来进一步说明本发明的技术方案。本领域技术人员应该明了,所述实施例仅仅是帮助理解本发明,不应视为对本发明的具体限制。
具体实施方式部分涉及到的部分原料信息如下所示:
EVA:EVA 40LX,来源于上海懂高化工;
POE:来源于宁波天元石化;
改性氢氧化镁:来源于烟台艾弗尔;
改性氢氧化铝:来源于上海维杰;
防霉剂:来源于南京天诗蓝盾生物科技。
实施例1~3
一种耐霉菌型无卤橡胶护套材料,包括如表1所示组分,其中,各个组分的用量均为“重量份”:
表1
组分 | 实施例1 | 实施例2 | 实施例3 |
EVA 40LX | 100 | 100 | 100 |
POE | 10 | 5 | 15 |
改性氢氧化镁 | 80 | 70 | 90 |
改性氢氧化铝 | 20 | 10 | 30 |
白炭黑 | 20 | 15 | 25 |
防霉剂 | 10 | 8 | 12 |
微晶蜡 | 4 | 3 | 5 |
防老剂XH-3 | 3 | 2 | 4 |
炭黑N-330 | 3 | 2 | 4 |
硬脂酸 | 2 | 1 | 3 |
DOS | 4 | 3 | 5 |
偶联剂A-172 | 1 | 0.5 | 1.5 |
DCP | 4 | 3 | 5 |
TAIC | 2 | 1 | 3 |
所述耐霉菌型无卤橡胶护套材料的制备方法包括如下步骤:
(1)将所述EVA40LX和POE在110℃下,在密炼机中混炼2min,混炼均匀;
(2)在步骤(1)的密炼机中再加入改性氢氧化镁、改性氢氧化铝、白炭黑、防霉剂、微晶蜡、防老剂XH-3、高耐磨炭黑N-330、硬脂酸、DOS和偶联剂A-172,继续混炼5min,混炼均匀;
(3)在上述密炼机中最后加入DCP和TAIC,继续混炼1min,然后排出混炼胶料;
(4)将所述混炼胶料在开炼机上薄通2~3次,同时摆胶2~3次,接着在三辊压延机上开条出片,输出的橡页经过冷却辊冷却,过滑石粉箱后,即制得成品。
应用例1
一种电缆桥电缆,其剖面结构示意图如图1所示,包括中心导体1、所述中心导体1外依次包覆有半导电尼龙带层2、导体屏蔽层3、绝缘层4、绝缘屏蔽层5、第一半导电阻水带层6、镀锡铜丝疏绕屏蔽层7、第二半导电阻水带层8和橡胶护套层9;
其中,中心导体1为GB/T 3956标准规定的第5种圆形绞合镀锡软铜导体,导体表面光洁、无损伤绝缘的毛刺、锐边以及凸起或断裂的单线;
半导电尼龙带层2采用半导电尼龙带(来源于扬州腾飞,牌号为BNLD 12)重叠绕包的形式包覆在中心导体1上,重叠率为25%;
导体屏蔽层3采用66kV超洁净半导电内屏料(来源于上海利物通,牌号为PEJD-66kV),性能符合IEC 60840标准的规定;
绝缘屏蔽层5采用66kV超洁净不可剥离半导电外屏料(来源于上海利物通,牌号为PEJJ-66kV),性能符合IEC 60840标准的规定;
第一半导电阻水带层6为在绝缘屏蔽上重叠绕包的一层半导电阻水带(来源于扬州腾飞、牌号为ZDBS),重叠率为25%;
镀锡铜丝疏绕屏蔽层7采用镀锡圆铜丝螺旋式疏绕的方式缠绕在电缆线芯上,起到金属屏蔽接地故障载流的作用;
第二半导电阻水带层8为在绝缘屏蔽上重叠绕包的一层半导电阻水带(来源于扬州腾飞、牌号为ZDBS),重叠率为25%;
橡胶护套层9的材料为实施例1提供的耐霉菌型无卤橡胶护套材料。
应用例2~3
一种电缆桥电缆,其与应用例1的区别仅在于,分别采用实施例2~3提供的耐霉菌型无卤橡胶护套材料替换实施例1提供的耐霉菌型无卤橡胶护套材料作为橡胶护套层的材料,其他结构、参数和材料均与应用例1相同。
对比应用例1
一种电缆桥电缆,其与应用例1的区别仅在于,采用氯丁橡胶料(来源于镇江马弗、牌号为XH-08A-CR)替换实施例提供的耐霉菌型无卤橡胶护套材料作为橡胶护套层的材料,其他结构、参数和材料均与应用例1相同。
对比应用例2
一种电缆桥电缆,其与应用例1的区别仅在于,采用常规无卤橡胶料(来源于上海天留,牌号为LSOH-90)替换实施例提供的耐霉菌型无卤橡胶护套材料作为橡胶护套层的材料,其他结构、参数和材料均与应用例1相同。
对比应用例3
一种电缆桥电缆,其与应用例1的区别仅在于,采用半导电尼龙带分别替换第一半导电阻水带层和第二半导电阻水带层,其他结构、参数和材料均与应用例1相同。
性能测试:
(1)低烟性能:按GB/T 17651规定在特定条件下进行低烟性能测定,记载透光率;
(2)无卤性能:按GB/T 17650和IEC 60684-2规定进行燃烧试验,记录pH值、最大电导率、最大氯和溴含量和最大氟含量;
(3)金属屏蔽阻水性能:按GB/T 12706.2中附录F的中要求进行测试;
(4)耐霉菌性能:按照GJB 150.10A的规定进行测试。
按照上述测试方法对应用例1~3和对比应用例1~3提供的电缆桥电缆进行测试,测试结果如表2所示:
表2
根据表2数据可以看出:本发明提供的电缆桥电缆低烟性能、无卤性能、金属屏蔽阻水性能以及耐霉菌性能均很优异。
具体而言,应用例1~3提供的电缆桥电缆的透光率为65~72%,pH值为4.9~5.6,电导率为0.1~0.3μS/mm,氯和溴含量为0.05~0.2%,氟含量为0.03~0.05%,均能通过阻水测试,且耐霉菌等级为0~1级。比较应用例1和对比应用例1可以看出,采用氯丁橡胶料作为橡胶护套层的材料会导致得到的电缆的透光率较低,且耐霉菌性能为3级,耐霉菌性较差。
再比较应用例1和对比应用例2还可以发现,采用常规无卤橡胶料作为橡胶护套层的材料,同样会导致得到的电缆的透光率降低,低烟性能和耐霉菌性下降。
最后比较应用例1和对比应用例3的数据还可以发现,采用半导电尼龙带分别替换第一半导电阻水带层和第二半导电阻水带层,则会导致得到的电缆的阻水性能较差,不能通过阻水实验。
申请人声明,本发明通过上述实施例来说明一种耐霉菌型无卤橡胶护套材料和包含其电缆桥电缆,但本发明并不局限于上述工艺步骤,即不意味着本发明必须依赖上述工艺步骤才能实施。所属技术领域的技术人员应该明了,对本发明的任何改进,对本发明所选用原料的等效替换及辅助成分的添加、具体方式的选择等,均落在本发明的保护范围和公开范围之内。
Claims (10)
2.根据权利要求1所述的耐霉菌型无卤橡胶护套材料,其特征在于,所述阻燃剂包括改性氢氧化镁和改性氢氧化铝的组合;
优选地,所述耐霉菌型无卤橡胶护套材料中改性氢氧化镁的含量为70~90重量份;
优选地,所述耐霉菌型无卤橡胶护套材料中改性氢氧化铝的含量为10~30重量份。
3.根据权利要求1或2所述的耐霉菌型无卤橡胶护套材料,其特征在于,所述硫化剂包括过氧化二异丙苯和三烯丙基异三聚氰酸酯的组合;
优选地,所述耐霉菌型无卤橡胶护套材料中过氧化二异丙苯的含量为3~5重量份;
优选地,所述耐霉菌型无卤橡胶护套材料中三烯丙基异三聚氰酸酯的含量为1~3重量份;
优选地,所述增塑剂包括癸二酸二辛酯。
4.根据权利要求1~3任一项所述的耐霉菌型无卤橡胶护套材料,其特征在于,所述耐霉菌型无卤橡胶护套材料中还包括防老剂和/或偶联剂;
优选地,所述耐霉菌型无卤橡胶护套材料中防老剂的含量为2~4重量份;
优选地,所述耐霉菌型无卤橡胶护套材料中偶联剂的含量为0.5~1.5重量份。
5.一种如权利要求1~4任一项所述耐霉菌型无卤橡胶护套材料的制备方法,其特征在于,所述制备方法包括如下步骤:
(1)将EVA和POE进行混炼,得到第一混炼胶;
(2)将步骤(1)得到的混炼胶、阻燃剂、白炭黑、防霉剂、微晶蜡、炭黑、硬脂酸、增塑剂、任选地防老剂和任选地偶联剂进行混炼,得到第二混炼胶;
(3)将步骤(1)得到的第二混炼胶和硫化剂进行混炼,得到所述耐霉菌型无卤橡胶护套材料。
6.根据权利要求5所述的制备方法,其特征在于,步骤(1)所述混炼的时间为1~2min;
优选地,步骤(1)所述混炼的温度为105~115℃;
优选地,步骤(2)所述混炼的时间为4~5min;
优选地,步骤(2)所述混炼的温度为105~115℃;
优选地,步骤(3)所述混炼的时间为0.5~1min;
优选地,步骤(3)所述混炼的温度为105~115℃。
7.一种电缆桥电缆,其特征在于,所述电缆桥电缆包括中心导体,所述中心导体外依次包覆有半导电尼龙带层、导体屏蔽层、绝缘层、绝缘屏蔽层、第一半导电阻水带层、镀锡铜丝疏绕屏蔽层、第二半导电阻水带层和橡胶护套层;
所述橡胶护套层的材料包括如权利要求1~4任一项所述的耐霉菌型无卤橡胶护套材料。
8.根据权利要求7所述的电缆桥电缆,其特征在于,所述中心导体为绞合镀锡软铜导体。
9.根据权利要求7或8所述的电缆桥电缆,其特征在于,所述绝缘层的材料为EPR绝缘料。
10.一种如权利要求7~9任一项所述的电缆桥电缆在大功率风机塔中的应用。
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