CN116285157A - 高阻燃可塑性装配电缆及其制备工艺 - Google Patents
高阻燃可塑性装配电缆及其制备工艺 Download PDFInfo
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Abstract
本发明提供了高阻燃可塑性装配电缆及其制备工艺,涉及电缆制备技术领域,将多品种电缆集为一体用可塑性高阻燃套管予以固定,可塑性高阻燃套管包括以下质量比成分:45‑55份五型PVC树酯、15‑17份对苯二甲酸二辛脂、8‑10份邻苯二甲酸二辛、3‑5份氯化聚乙烯、0.1‑0.3份双酚A、0.1‑0.3份硬酯酸、5‑6份三氧化二铝、8‑9份氧化镁、3‑4份硼酸锌、0.15‑0.17份UV531;本发明根据配方配置制备可塑性高阻燃套管的材料,经过验证,设备螺膛压力减少35%,出料正常,制备的高阻燃可塑性装配电缆可90℃直角弯曲并且不会发生断裂,同时具有一定的柔韧性产品在墙面横向敷设后不会下垂。
Description
技术领域
本发明涉及电缆制备技术领域,尤其涉及高阻燃可塑性装配电缆及其制备工艺。
背景技术
电缆是一种电能或信号传输装置,通常是由单一品种组成,电缆有电源线、监控线、数据线、光缆、高温电缆、计算机电缆、信号电缆、同轴电缆、耐火电缆、船用电缆、矿用电缆、铝合金电缆等等,它们都是由单股或多股导线和绝缘层组成,用来连接电路、电器等;随着经济建设的高速发展,电气化、网络通信不断进步,与此同时电气故障引发的火灾也在逐年上升,在电气故障引发的火灾中电线电缆原因引发的火灾比例又占首位,面对这种传统单一品种结构的电缆已经不能满足电气化、网络通信不断进步的需求,尤其不能满足当前商务楼、综合性办公大楼、娱乐场所、医院、家装、学校等用电线电缆多元化的需求;
电缆需要在生产过程中完成穿线这一过程,传统技术中,一般使用全硬质阻燃PVC套管材料,对产品容易折断、过硬、不易弯曲、无法直接穿线或导管太软无法定型,浪费材料,影响安装效率,因此,本发明提出高阻燃可塑性装配电缆及其制备工艺以解决现有技术中存在的问题。
发明内容
针对上述问题,本发明提出高阻燃可塑性装配电缆及其制备工艺,该高阻燃可塑性装配电缆及其制备工艺制备的高阻燃可塑性装配电缆可90℃直角弯曲并且不会发生断裂,同时具有一定的柔韧性产品在墙面横向敷设后不会下垂。
为实现本发明的目的,本发明通过以下技术方案实现:高阻燃可塑性装配电缆,将多品种电缆集为一体用可塑性高阻燃套管予以固定,可塑性高阻燃套管包括以下质量比成分:45-55份五型PVC树酯、15-17份对苯二甲酸二辛脂、8-10份邻苯二甲酸二辛、3-5份氯化聚乙烯、0.1-0.3份双酚A、0.1-0.3份硬酯酸、5-6份三氧化二铝、8-9份氧化镁、3-4份硼酸锌、0.15-0.17份UV531、0.14-0.16份联苯胺黄、3-4份钙/锌复合粉。
进一步改进在于:可塑性高阻燃套管包括以下质量比成分:50份五型PVC树酯、16份对苯二甲酸二辛脂、9份邻苯二甲酸二辛、4份氯化聚乙烯、0.2份双酚A、0.2份硬酯酸、5.5份三氧化二铝、8.24份氧化镁、3.05份硼酸锌、0.16份UV531、0.15份联苯胺黄、3.5份钙/锌复合粉。
高阻燃可塑性装配电缆的制备工艺,包括以下步骤:
S1:制备可塑性高阻燃套管的材料;
S2:装配电缆各单根缆芯进行挤包,完成后将装配电缆多根缆芯装入挤塑机放线架;
S3:根据可塑性高阻燃套管材料的挤出温度设定挤塑机各段工艺温度,在工艺温度达到前将组合电缆的各根缆芯装入分线定位装置;
S4:挤塑工艺温度达到后将分线定位后的多根缆芯综合穿入模芯,利用模具和充气的压力将可塑性高阻燃套管材料挤出形成波纹套管;
S5:根据挤包直径调整挤塑机螺杆或牵引速度控制波纹套管的厚度,固定缆芯,固定后进行水冷却定形;
S6:将成形后的装配电缆通过牵引和排线装置收入电缆盘,对成品检验及电缆分割包装。
进一步改进在于:所述S1包括以下步骤:
S11:将高速混料机预热,先将PVC树酯、对苯二甲酸二辛脂、邻苯二甲酸二辛和氯化聚乙烯倒入高速混料机搅拌;
S12:将硼酸锌倒入高速混料机搅拌,再将硬酯酸、三氧化二铝和氧化镁倒入高速混料机搅拌;
S13:将双酚A和UV531倒入高速混料机搅拌,10min后再将联苯胺黄和钙/锌复合粉倒入高速混料机搅拌;
S14:打开高速混料机放料盖出料,将混合成的阻燃发泡粉料送到造粒机造粒,成形后的颗粒阻燃料进入装配电缆生产工序。
进一步改进在于:所述S11中,高速混料机预热60-80℃,PVC树酯、对苯二甲酸二辛脂、邻苯二甲酸二辛和氯化聚乙烯搅拌2-3min。
进一步改进在于:所述S12中,加入硼酸锌搅拌1-2min,加入硬酯酸、三氧化二铝和氧化镁搅拌1-2min。
进一步改进在于:所述S13中,加入双酚A和UV531搅拌1-2min,加入联苯胺黄和钙/锌复合粉搅拌3-5min。
进一步改进在于:所述S3中,在工艺温度达到前,将组合电缆的各根缆芯引入分线板后导入集束孔,将集束在充气管内的电缆芯和牵引线连接。
进一步改进在于:所述S4中,工艺温度达到后,打开气压泵,向模具充气管道进行充气,模具包括内模、外模和充气管,外模采用锥形斜度角吻合在机头模座的前端模座位置上,内模采用锥形斜度角固定在机头模座后端模座位置上,充气管与机头模座尾部连接套的螺纹连接,电缆通过机头外部的分线板和集束孔将各根缆芯集束在充气管的孔道内,在牵引线的牵引下将电缆引出模具,在充气管的孔道内时,充气管进入充气工作,通过充气管两侧充气通道的气体压力使可塑性高阻燃套管材料在挤塑过程中形成管状,粘附在电缆的缆芯表面上。
本发明的有益效果为:
1、本发明根据配方配置制备可塑性高阻燃套管的材料,经过验证,设备螺膛压力减少35%,出料正常,制备的高阻燃可塑性装配电缆可90℃直角弯曲并且不会发生断裂,同时具有一定的柔韧性产品在墙面横向敷设后不会下垂。
2、本发明生产的电缆在230℃的燃烧温度下其材料不起烟雾,物理属性稳定,并具有耐酸碱性,具备良好冷内热属性,并经过阻燃配方设计,提高阻燃效果,降低火灾风险。
3、本发明制备的电缆不用人工穿管,直接敷设,由于具有较好的柔韧性敷设中可以减少弯头的使用,降低敷设成本;缩短安装敷设的施工周期,提高施工效率。
附图说明
图1为本发明的高阻燃可塑性装配电缆的制备工艺图;
图2为本发明的可塑性高阻燃套管材料的制备工艺图;
图3为现有技术外模剖视图;
图4为现有技术内模示意图;
图5为本发明的外模剖视图;
图6为本发明的内模剖视图;
图7为本发明的充气管剖视图。
具体实施方式
为了加深对本发明的理解,下面将结合实施例对本发明做进一步详述,本实施例仅用于解释本发明,并不构成对本发明保护范围的限定。
实施例一
本实施例提出了高阻燃可塑性装配电缆,将多品种电缆集为一体用可塑性高阻燃套管予以固定,可塑性高阻燃套管包括以下质量比成分:50份五型PVC树酯、16份对苯二甲酸二辛脂、9份邻苯二甲酸二辛、4份氯化聚乙烯、0.2份双酚A、0.2份硬酯酸、5.5份三氧化二铝、8.24份氧化镁、3.05份硼酸锌、0.16份UV531、0.15份联苯胺黄、3.5份钙/锌复合粉。
对苯二甲酸二辛脂和邻苯二甲酸二辛共用以提高高阻燃套管材料的可塑性和绝缘性能,投入氯化聚乙烯以改善材料的柔软性能。由于材料主体成分是聚氯乙烯树酯其分子结构中有氯分子的存在,该分子热稳定性能较差并且分子特性很活跃,在主体材料和增塑剂、柔性剂进入高速搅拌混炼机后应马上投入硼酸锌以稳定氯分子的活跃性。为减少材料在高速搅拌混炼中的热摩擦和提高材料的阻燃性能,应投入硬酯酸、三氧化二铝和氧化镁。为防止材料的氧老化和提高材料的抗紫外线老化应该投入双酚和UV531。在确定材料颜色后同时尽量降低材料成本的原则,应投入联苯胺黄着色剂和钙/锌复合粉填充剂。这样的配方原理既提高了材料的阻燃性、可塑性,又提高了材料的柔软性。
实施例二
根据图1和图2所示,本实施例提出了高阻燃可塑性装配电缆的制备工艺,其特征在于,包括以下步骤:
S1:制备可塑性高阻燃套管的材料;
S11:将高速混料机预热60-80℃,先将PVC树酯、对苯二甲酸二辛脂、邻苯二甲酸二辛和氯化聚乙烯倒入高速混料机搅拌2-3min;
S12:将硼酸锌倒入高速混料机搅拌1-2min,再将硬酯酸、三氧化二铝和氧化镁倒入高速混料机搅拌1-2min;
S13:将双酚A和UV531倒入高速混料机搅拌1-2min,10min后再将联苯胺黄和钙/锌复合粉倒入高速混料机搅拌3-5min;
S14:打开高速混料机放料盖出料,将混合成的阻燃发泡粉料送到造粒机造粒,成形后的颗粒阻燃料进入装配电缆生产工序;
S2:装配电缆各单根缆芯进行挤包,完成后将装配电缆多根缆芯装入挤塑机放线架;
S3:根据可塑性高阻燃套管材料的挤出温度设定挤塑机各段工艺温度,在工艺温度达到前,将组合电缆的各根缆芯引入分线板后导入集束孔,将集束在充气管内的电缆芯和牵引线连接;
S4:挤塑工艺温度达到后将分线定位后的多根缆芯综合穿入模芯,工艺温度达到后,打开气压泵,向模具充气管道进行充气,利用模具和充气的压力将可塑性高阻燃套管材料挤出形成波纹套管;
S5:根据挤包直径调整挤塑机螺杆或牵引速度控制波纹套管的厚度,固定缆芯,固定后进行水冷却定形;
S6:将成形后的装配电缆通过牵引和排线装置收入电缆盘,对成品检验及电缆分割包装。
本发明按上述配方配置生产制备可塑性高阻燃套管的材料,经过验证,设备螺膛压力减少35%,出料正常,制备的高阻燃可塑性装配电缆可90℃直角弯曲并且不会发生断裂,同时具有一定的柔韧性产品在墙面横向敷设后不会下垂。
综上,本发明生产的高阻燃可塑性装配电缆,弯曲性能良好,具有较好的柔韧性,不易变形,弯曲半径小可在90℃直角弯曲,施工简单快捷,适应于多种场合,其产品在230℃的燃烧温度下其材料不起烟雾,物理属性稳定,并具有一定的耐酸碱性,其使用寿命相比普通材质的导管要长出十多年;面对不同环境高温低温表现稳定,具备良好冷内热属性,应用领域广泛,适用于温差较大的室内户外工程;同时,经过阻燃配方设计,配方中加入不同比例和不同类别的阻燃剂(三氧化二铝、氧化镁),提高高阻燃套管材料的阻燃效果,降低火灾风险。
本发明制备的高阻燃可塑性装配电缆不用人工穿管,直接敷设;由于具有较好的柔韧性敷设中可以减少弯头的使用,降低敷设成本;减少电源线和电工管的采购环节,管线一体一次性采购直接使用;缩短安装敷设的施工周期,提高施工效率,家装电气敷设项目交付快;解决了住宅装修时电缆的直角拐弯和防止电缆在使用期间的下垂现象。
实施例三
根据图5-图7所示,本实施例提出了可塑性装配电缆生产用挤塑模具,包括包括内模、外模和充气管,外模采用锥形斜度角吻合在机头模座的前端模座位置上,这种锥形斜度角吻合,工件配合紧密不易松动,内模采用锥形斜度角固定在机头模座后端模座位置上,充气管与机头模座尾部连接套的螺纹连接,电缆通过机头外部的分线板和集束孔将各根缆芯集束在充气管的孔道内,在牵引线的牵引下将电缆引出模具,在充气管的孔道内时,充气管进入充气工作,通过充气管两侧充气通道的气体压力使可塑性高阻燃套管材料在挤塑过程中形成管状,粘附在电缆的缆芯表面上。
电线电缆产品的质量好坏,与塑料本身的质量、挤出机的性能、挤出温度、收放线张力、速度、芯线预热、塑料挤出冷却、挤塑模具设计等多种因素有关,其中最主要的是电线电缆挤出过程中最后定型的装置---模具。由于现有技术重病普通模具(见图3和图4)不能满足高阻燃可塑性装配电缆的生产要求,使用普通模具挤出,会出现集束后的缆芯不能有效的和套管结合,会出现出料压力不均匀,造成波纹管塌瘪缺陷,针对这些问题,使用充气式的可塑性装配电缆挤塑模具,解决了这一问题。由于使用普通模具会造成波纹管塌瘪缺陷,根本无法控制套管厚度和外观的圆整度,充气式可塑性装配电缆挤塑模具,利用气体的压力將挤出胶层吹开,在外模壁的压力下使套管整度。从图5-图7可以看出由于充气式可塑性装配电缆挤塑的外模、内模和充气管都要比普通模具(图3和图4)长,物料在充气压力下的畅通流出。
本实施例中,挤出的塑胶层表面光滑,塑胶层厚度均匀;
模具的推动压力大,有效的增加了出胶料量,提高了生产效益;
由于外模、内模和充气管三者的同心度一致,挤出层不会偏芯;
由于外模、内模和充气管三者的长度比普通模具要长,使胶料在模具内的定向时间比较长,有利于套管的物理机械性能中的拉伸定向强度;
由于使用了充气管胶料对模具壁的摩擦力减少,提高了模具的使用寿命。
以上显示和描述了本发明的基本原理、主要特征和优点。本行业的技术人员应该了解,本发明不受上述实施例的限制,上述实施例和说明书中描述的只是说明本发明的原理,在不脱离本发明精神和范围的前提下,本发明还会有各种变化和改进,这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。
Claims (9)
1.高阻燃可塑性装配电缆,将多品种电缆集为一体用可塑性高阻燃套管予以固定,其特征在于,可塑性高阻燃套管包括以下质量比成分:45-55份五型PVC树酯、15-17份对苯二甲酸二辛脂、8-10份邻苯二甲酸二辛、3-5份氯化聚乙烯、0.1-0.3份双酚A、0.1-0.3份硬酯酸、5-6份三氧化二铝、8-9份氧化镁、3-4份硼酸锌、0.15-0.17份UV531、0.14-0.16份联苯胺黄、3-4份钙/锌复合粉。
2.根据权利要求1所述的高阻燃可塑性装配电缆,其特征在于:可塑性高阻燃套管包括以下质量比成分:50份五型PVC树酯、16份对苯二甲酸二辛脂、9份邻苯二甲酸二辛、4份氯化聚乙烯、0.2份双酚A、0.2份硬酯酸、5.5份三氧化二铝、8.24份氧化镁、3.05份硼酸锌、0.16份UV531、0.15份联苯胺黄、3.5份钙/锌复合粉。
3.高阻燃可塑性装配电缆的制备工艺,其特征在于,包括以下步骤:
S1:制备可塑性高阻燃套管的材料;
S2:装配电缆各单根缆芯进行挤包,完成后将装配电缆多根缆芯装入挤塑机放线架;
S3:根据可塑性高阻燃套管材料的挤出温度设定挤塑机各段工艺温度,在工艺温度达到前将组合电缆的各根缆芯装入分线定位装置;
S4:挤塑工艺温度达到后将分线定位后的多根缆芯综合穿入模芯,利用模具和充气的压力将可塑性高阻燃套管材料挤出形成波纹套管;
S5:根据挤包直径调整挤塑机螺杆或牵引速度控制波纹套管的厚度,固定缆芯,固定后进行水冷却定形;
S6:将成形后的装配电缆通过牵引和排线装置收入电缆盘,对成品检验及电缆分割包装。
4.根据权利要求3所述的高阻燃可塑性装配电缆的制备工艺,其特征在于:所述S1包括以下步骤:
S11:将高速混料机预热,先将PVC树酯、对苯二甲酸二辛脂、邻苯二甲酸二辛和氯化聚乙烯倒入高速混料机搅拌;
S12:将硼酸锌倒入高速混料机搅拌,再将硬酯酸、三氧化二铝和氧化镁倒入高速混料机搅拌;
S13:将双酚A和UV531倒入高速混料机搅拌,10min后再将联苯胺黄和钙/锌复合粉倒入高速混料机搅拌;
S14:打开高速混料机放料盖出料,将混合成的阻燃发泡粉料送到造粒机造粒,成形后的颗粒阻燃料进入装配电缆生产工序。
5.根据权利要求4所述的高阻燃可塑性装配电缆的制备工艺,其特征在于:所述S11中,高速混料机预热60-80℃,PVC树酯、对苯二甲酸二辛脂、邻苯二甲酸二辛和氯化聚乙烯搅拌2-3min。
6.根据权利要求5所述的高阻燃可塑性装配电缆的制备工艺,其特征在于:所述S12中,加入硼酸锌搅拌1-2min,加入硬酯酸、三氧化二铝和氧化镁搅拌1-2min。
7.根据权利要求6所述的高阻燃可塑性装配电缆的制备工艺,其特征在于:所述S13中,加入双酚A和UV531搅拌1-2min,加入联苯胺黄和钙/锌复合粉搅拌3-5min。
8.根据权利要求3所述的高阻燃可塑性装配电缆的制备工艺,其特征在于:所述S3中,在工艺温度达到前,将组合电缆的各根缆芯引入分线板后导入集束孔,将集束在充气管内的电缆芯和牵引线连接。
9.根据权利要求3所述的高阻燃可塑性装配电缆的制备工艺,其特征在于:所述S4中,工艺温度达到后,打开气压泵,向模具充气管道进行充气,模具包括内模、外模和充气管,外模采用锥形斜度角吻合在机头模座的前端模座位置上,内模采用锥形斜度角固定在机头模座后端模座位置上,充气管与机头模座尾部连接套的螺纹连接,电缆通过机头外部的分线板和集束孔将各根缆芯集束在充气管的孔道内,在牵引线的牵引下将电缆引出模具,在充气管的孔道内时,充气管进入充气工作,通过充气管两侧充气通道的气体压力使可塑性高阻燃套管材料在挤塑过程中形成管状,粘附在电缆的缆芯表面上。
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