CN116564600A - 一种柔性防火电缆及其制备方法 - Google Patents
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Abstract
本发明涉及电缆技术领域,尤其涉及IPC H01B7,更具体地涉及,一种柔性防火电缆及其制备方法。本发明中的柔性防火电缆,包括导体、耐火层、绝缘层、矿物质填充层、高阻燃层、护套层。本发明中的柔性防火电缆的制备方法为连拉连退、绞线、绕包云母带、挤包绝缘、成缆、挤包矿物质填充层、绕包高阻燃层、挤包外护套。本发明中的柔性防火电缆的外护套具有柔性、防火、低烟、无卤、耐温、耐火、载流量大、机械强度高的特点。
Description
技术领域
本发明涉及电缆技术领域,尤其涉及IPC H01B7,更具体地涉及,一种柔性防火电缆及其制备方法。
背景技术
随着现代化的发展,人口的增长,建筑的层数不断地增加,一旦火灾发生,将造成巨大的生命财产的损失。在现代化的生活中,各种电器必不可少,运输电力的主干线路的主要为防火电缆。随着消防意识的提高,越来越多的防火电缆被要求应用于建筑的建设中。各种厂家对防火电缆的性能要求也越来越高。
现有专利CN202020522480.9公开了一种刚性矿物绝缘电缆,在导体外部设置外被层、绑扎带、绝缘屏蔽层、PE绝缘层、和屏蔽层,有较好的阻燃效果,能接受较强的外力冲击,但矿物绝缘电缆需要使用专用接头,增加了材料和人工成本,且其防火阻燃性能还有待进一步加强。
因此,需要开发一种防火性能强,材料人工成本低,且制备过程中产品合格率高的柔性防火电缆。
发明内容
为了解决现有技术中的问题,本发明第一方面提供了一种柔性防火电缆,包括导体、耐火层、绝缘层、矿物质填充层、高阻燃层、护套层;所述导体有多个,导体外层绕包耐火层,耐火层外层包覆绝缘层,多个导体外层绕包高阻燃层,高阻燃层和多个导体之间挤包矿物质填充层,所述高阻燃层外层包覆护套层。
优选的,所述导体为3个。
优选的,所述导体的横截面积为16.00mm2的铜丝。
优选的,所述耐火层为云母带。
优选的,所述云母带的厚度为0.14mm,宽度为25mm,购自湖北平安电工材料有限公司,订货号为23012。
优选的,所述耐火层的厚度为0.45mm。
优选的,所述绝缘层为交联聚乙烯。
优选的,所述交联聚乙烯包括高能辐照交联的交联聚乙烯、硅烷交联聚乙烯、辐照交联聚乙烯中的任意一种;进一步优选的,为高能辐照交联的交联聚乙烯。
优选的,所述绝缘层的标称厚度为0.6mm。
优选的,高能辐照交联的交联聚乙烯购自优唯新材料科技有限公司,牌号为UV-90。
优选的,所述矿物质填充层包括氧化铝、氢氧化镁一种或两种和硅酸钠;进一步优选的,为氢氧化镁与硅酸钠。
优选的,所述氢氧化镁为纳米级氢氧化镁。
优选的,所述氢氧化镁与硅酸钠的质量比为(15~20):23;进一步优选的,为18:25。
优选的,所述氢氧化镁与硅酸钠的混合物购自东莞市崇峻化工材料有限公司。
本发明中,通过添加在矿物填充层中添加采用国内外先进纳米技术研制的氢氧化镁与硅酸钠的混合物,能提高柔性防火电缆的耐火性、隔热性,且成本低廉。本发明人发现,传统的刚性矿物绝缘电缆以氧化镁粉末为绝缘层,容易产生厚薄不均的现象,工艺稍有差池便会被击穿,额定电压最高为450/750V,且单根连续长度有限,安装过程中需要不断使用接头、增加人力和财力成本,本申请中柔性防火电缆,包括导体、耐火层、绝缘层、矿物质填充层、高阻燃层、护套层,其中矿物填充层中的填充物为纳米级氢氧化镁与硅酸钠的混合物,具有高防火性。本发明人推测,柔性防火电缆的主要成分是氢氧化镁与硅酸钠的混合物,它本身不会引起火灾,不能燃烧或助燃,且具有1500℃以上的较高熔点,在火焰条件下也能发挥正常的输电。纳米级的氢氧化镁与硅酸钠的混合物,形成厚薄均匀的矿物填充层,工艺简单,额定电压的范围广。
优选的,所述高阻燃层为玻璃阻燃包带。
优选的,所述玻璃阻燃包带的耐温温度为600℃,购自宁晋县昊鑫电缆材料经销部。
优选的,所述外护套为低烟无卤聚烯烃。
优选的,所述低烟无卤聚烯烃购自上海欧伯尔新材料有限公司,型号为WDZ-Y-90。
本发明第二方面提供了一种柔性防火电缆的制备方法,包括以下步骤:
S1:连拉连退:在连拉连退装置中放置铜丝,通过导轮、拉丝模拉制成所需直径的铜丝,设置连拉连退装置的电压为35~40V,电流为650~750A,拉丝速度为350~400米/分钟;
S2:绞线:将S1中获得的相同直径的铜丝置于盘式绞线机上进行绞合,得到所需的导体;
S3:绕包云母带:将S2中获得的导体分别穿过线导轮、绕包头、定线模拉至包膜前、穿过导线模、将牵引线接在一起,然后将云母带粘在铜线芯上,然后缓慢开机,进行绕包,得到绕包云母带的导体;
S4:挤包绝缘和交联:在挤塑机料筒中加入交联聚乙烯,设置机身温度:设置机身温度:一区165~175℃,二区170~180℃,三区175~185℃,四区180~190℃、五区182~192℃、设置机头温度:机头(六区)182~192℃、机脖(七区)180~190℃、机头(八区)190~200℃,将S3中绕包云母带的导体由带张力调节的放线架经导轮装置进入挤塑机模具中进行挤塑,形成绝缘层包覆的导体;紧接着通过辐照交联机进行交联,设置交联参数,得到挤包绝缘的导体;
S5:成缆:将S4中挤包绝缘的导体固定在成缆机上,按顺序排列,设置成缆线芯节距,将成缆线芯穿过并线模,成缆芯;
S6:挤包矿物质填充层:在挤塑机的料筒中加入人工搅拌好的无机矿物质防火材料,将S5中获得的缆芯由带张力调节的放线架经导轮装置进入挤塑机模具,开启主机及收线装置,在缆芯及缆芯中央和间隙挤包无机矿物质材料,形成圆整的矿物质填充层;
S7:绕包高阻燃层:将S6中获得的缆芯分别穿过线导轮、绕包头、定线模拉至包膜前、穿过导线模、将牵引线接在一起,然后将玻璃阻燃包带粘在S6中获得的缆芯上,然后缓慢开机,进行绕包;
S8:挤包外护套:在挤塑机料筒中加入低烟无卤聚烯烃,设置机身温度:一区85~90℃,二区105~110℃,三区130~135℃,四区135~140℃,五区135~140℃;设置机头温度:机头(六区)115~120℃,机脖(七区)115~120℃,机头(八区)135~140℃;将S7中获得的缆芯由带张力调节的放线架经导轮装置进入挤塑机模具中进行挤塑,形成柔性防火电缆。
优选的,所述S1中的铜丝直径为3mm;所需铜丝的直径为1.7mm。
优选的,导体的横截面为16mm2。
优选的,所述S4中交联参数为:光照强度80~90%,出线速度35~45m/min;进一步优选的,为光照强度90%,出线速度40±2m/min。
优选的,所述S5中的缆线芯节距为480~560mm。
本发明中,通过设置连拉连退装置的电压为35~40V,电流为650~750A,拉丝速度为350~400米/分钟,得到均匀粗细的铜线,提供了产品的合格率。本发明人发现,若电拉丝速度过慢过慢,形成的铜丝,无法达到标准,需要重新调试,进行拉丝,得到符合标准的铜丝。
本发明中,通过控制S4中挤塑机通过控制S4中设置挤塑机的机身温度:一区165~175℃,二区170~180℃,三区175~185℃,四区180~190℃、五区182~192℃、设置机头温度:机头(六区)182~192℃、机脖(七区)180~190℃、机头(八区)190~200℃,使交联聚乙烯在云母带表面均匀平整的形成一层绝缘层。本发明人发现,当S4中挤塑机中的温度低于155℃,螺杆旋转速度不变时,制备得到的绝缘层不平整,其抗张强度小于12.5N/mm2,当挤塑机中各区的温度依次增加15℃,在相同冷却时间内得到的绝缘层过软,甚至产生气泡。
有益效果
1、本发明中,通过设置连拉连退装置的电压为35~40V,电流为650~750A,拉丝速度为350~400米/分钟,得到均匀粗细的铜线,提供了产品的合格率。
2、本发明中,通过控制S4中设置挤塑机的机身温度:一区165~175℃,二区170~180℃,三区175~185℃,四区180~190℃、五区182~192℃、设置机头温度:机头(六区)182~192℃、机脖(七区)180~190℃、机头(八区)190~200℃,使绝缘层均匀平整的在云母带表面形成一层绝缘层。
3、本发明中,通过添加在矿物填充层中添加采用国内外先进纳米技术研制的氢氧化镁与硅酸钠的混合物,能提高柔性防火电缆的耐火性、隔热性。
4、本发明中采用低烟无卤聚烯作为柔性防火电缆的外护套,没有通常的PVC材料,在火灾的条件下,也无酸性气体发散。
5、本发明中的柔性防火电缆的外护套具有柔性、防火、低烟、无卤、耐温、奈夫、载流量大、机械强度高的特点。
附图说明
图1为实施例1中制备得到的柔性防火电缆的截面图;1为导体、2为耐火层、3为绝缘层、4为矿物质填充层、5为高阻燃层、6为护套层。
具体实施方式
实施例1
本实施例第一方面提供了一种柔性防火电缆,为导体、耐火层、绝缘层、矿物质填充层、高阻燃层、护套层;所述导体有3个,导体外层绕包耐火层,耐火层外层包覆绝缘层,3个导体外层绕包高阻燃层,高阻燃层和3个导体之间挤包矿物质填充层,所述高阻燃层外层包覆护套层。
所述导体的横截面积为16.00mm2的铜丝。
所述耐火层为云母带。
所述云母带的厚度为0.14mm,宽度为25mm,购自湖北平安电工材料有限公司,订货号为23012。
所述耐火层的厚度为0.45mm。
所述绝缘层为交联聚乙烯。
高能辐照交联的交联聚乙烯。
所述绝缘层的标称厚度为0.6mm。
高能辐照交联的交联聚乙烯购自优唯新材料科技有限公司,牌号为UV-90。
所述矿物质填充层为氢氧化镁和硅酸钠。
所述氢氧化镁为纳米级氢氧化镁。
所述氢氧化镁和硅酸钠的质量比为18:25。
所述氢氧化镁购自东莞市崇峻化工材料有限公司。
所述硅酸钠购自廊坊乾耀科技有限公司。
所述高阻燃层为玻璃阻燃包带。
所述玻璃阻燃包带的耐温温度为600℃,购自宁晋县昊鑫电缆材料经销部。
所述外护套为低烟无卤聚烯烃。
所述低烟无卤聚烯烃购自特诺尔爱佩斯公司,牌号为58350。
本实施例第二方面提供了一种柔性防火电缆的制备方法,包括以下步骤:
S1:连拉连退:在连拉连退装置中放置直径为3.00mm的铜丝,通过导轮、拉丝模拉制成直径为1.7mm的铜丝,设置连拉连退装置的电压为40V,电流为750A,拉丝速度为400米/分钟;
S2:绞线:将S1中获得的相同直径的7根铜丝置于盘式绞线机上进行绞合,得到横截面为16mm2的导体;
S3:绕包云母带:将S2中获得的导体分别穿过线导轮、绕包头、定线模拉至包膜前、穿过导线模、将牵引线接在一起,然后将云母带粘在铜线芯上,然后缓慢开机,进行绕包,得到绕包云母带的导体;
S4:挤包绝缘和交联:在挤塑机料筒中加入交联聚乙烯,设置机身温度:一区170℃,二区175℃,三区180℃,四区185℃、五区187℃、设置机头温度:机头(六区)187℃、机脖(七区)185℃、机头(八区)185℃,将S3中绕包云母带的导体由带张力调节的放线架经导轮装置进入挤塑机模具中进行挤塑,形成绝缘层包覆的导体;紧接着通过辐照交联机进行交联,交联参数为:光照强度90%,出线速度40±2m/min,得到挤包绝缘的导体;
S5:成缆:将S4中得到的3根挤包绝缘的导体固定在成缆机上,按顺序排列,设置成缆线芯节距,将成缆线芯穿过并线模,成缆芯;
S6:挤包矿物质填充层:在挤塑机的料筒中加入人工搅拌好的纳米级的氢氧化镁与硅酸钠的混合物,将S5中获得的缆芯由带张力调节的放线架经导轮装置进入挤塑机模具,开启主机及收线装置,在缆芯及缆芯中央和间隙挤包无机矿物质材料,形成圆整的矿物质填充层;
S7:绕包高阻燃层:将S6中获得的缆芯分别穿过线导轮、绕包头、定线模拉至包膜前、穿过导线模、将牵引线接在一起,然后将玻璃阻燃包带粘在S6中获得的缆芯上,然后缓慢开机,进行绕包;
S8:挤包外护套:在挤塑机料筒中加入低烟无卤聚烯烃,设置机身温度:一区90℃,二区110℃,三区135℃,四区140℃,五区140℃;设置机头温度:机头(六区)120℃,机脖(七区)120℃,机头(八区)140℃;将S7中获得的缆芯由带张力调节的放线架经导轮装置进入挤塑机模具中进行挤塑,形成柔性防火电缆。
对比例1
对比例1的具体实施方式同实施例1一样,不同之处在于,所述S4中设置机身温度:一区155℃,二区160℃,三区165℃,四区170℃、五区172℃、设置机头温度:机头(六区)172℃、机脖(七区)170℃、机头(八区)170℃。
对比例1中制备得到的绝缘层表面粗糙,不光滑。
对比例2
对比例2的具体实施方式同实施例1一样,不同之处在于,所述S5中交联参数为光照强度90%,出线速度20±2m/min。
对比例3
对比例3的具体实施方式同实施例1一样,不同之处在于,所述矿物质填充层为氢氧化镁和硅酸钠的质量比为31:25。
得到的矿物填充层不成型,容易有粉末掉出。
性能测试
1、选取实施例1和对比例1、2中挤包绝缘层后的导体中交联聚乙烯绝缘1m作为试样,根据国标GB/T 2951.11,测试试样的抗张强度和断裂伸长率。结果见表1。
表1
抗张强度(N/mm2) | 断裂伸长率(%) | |
实施例1 | 18.6 | 530 |
对比例1 | 16.6 | 420 |
对比例2 | 16.4 | 450 |
2、选取实施例1中制备得到的柔性防火电缆10m作为试样,按照BS6387C、W、Z的标准进行实验。结果见表2。
表2
试验 | 结果 |
单纯防火试验C级,直接受火温度950±40℃,燃烧180min | 通过 |
防水防火实验W级:650℃,先燃烧15min,再燃烧喷淋15min | 通过 |
防火防撞试验Z级:950℃,15min/30次 | 通过 |
3、选取实施例1中制备得到的柔性防火电缆1m作为试样,根据IEC1034进行烟气发散试验,测试透光度达到90%。
Claims (10)
1.一种柔性防火电缆,其特征在于,包括导体、耐火层、绝缘层、矿物质填充层、高阻燃层、护套层;所述导体有多个,导体外层绕包耐火层,耐火层外层包覆绝缘层,多个导体外层绕包高阻燃层,高阻燃层和多个导体之间挤包矿物质填充层,所述高阻燃层外层包覆护套层。
2.根据权利要求1所述的一种柔性防火电缆,其特征在于,所述耐火层为云母带。
3.根据权利要求1所述的一种柔性防火电缆,其特征在于,所述绝缘层为交联聚乙烯。
4.根据权利要求3所述的一种柔性防火电缆,其特征在于,所述交联聚乙烯包括高能辐照交联的交联聚乙烯、硅烷交联聚乙烯、辐照交联聚乙烯中的任意一种。
5.根据权利要求1所述的一种柔性防火电缆,其特征在于,所述矿物质填充层包括氧化铝、氢氧化镁一种或两种和硅酸钠。
6.根据权利要求1所述的一种柔性防火电缆,其特征在于,所述高阻燃层为玻璃阻燃包带。
7.根据权利要求1所述的一种柔性防火电缆,其特征在于,所述外护套为低烟无卤聚烯烃。
8.一种根据权利要求1~7任一项所述的一种柔性防火电缆的制备方法,其特征在于,包括以下步骤:
S1:连拉连退:在连拉连退装置中放置铜丝,通过导轮、拉丝模拉制成所需直径的铜丝,设置连拉连退装置的电压为35~40V,电流为650~750A,拉丝速度为350~400米/分钟;
S2:绞线:将S1中获得的相同直径的铜丝置于盘式绞线机上进行绞合,得到所需的导体;
S3:绕包云母带:将S2中获得的导体分别穿过线导轮、绕包头、定线模拉至包膜前、穿过导线模、将牵引线接在一起,然后将云母带粘在铜线芯上,然后缓慢开机,进行绕包,得到绕包云母带的导体;
S4:挤包绝缘和交联:在挤塑机料筒中加入交联聚乙烯,设置机身温度:设置机身温度:一区165~175℃,二区170~180℃,三区175~185℃,四区180~190℃、五区182~192℃、设置机头温度:机头六区182~192℃、机脖七区180~190℃、机头八区190~200℃,将S3中绕包云母带的导体由带张力调节的放线架经导轮装置进入挤塑机模具中进行挤塑,形成绝缘层包覆的导体;紧接着通过辐照交联机进行交联,设置交联参数,得到挤包绝缘的导体;
S5:成缆:将S4中挤包绝缘的导体固定在成缆机上,按顺序排列,设置成缆线芯节距,将成缆线芯穿过并线模,成缆芯;
S6:挤包矿物质填充层:在挤塑机的料筒中加入人工搅拌好的无机矿物质防火材料,将S5中获得的缆芯由带张力调节的放线架经导轮装置进入挤塑机模具,开启主机及收线装置,在缆芯及缆芯中央和间隙挤包无机矿物质材料,形成圆整的矿物质填充层;
S7:绕包高阻燃层:将S6中获得的缆芯分别穿过线导轮、绕包头、定线模拉至包膜前、穿过导线模、将牵引线接在一起,然后将玻璃阻燃包带粘在S6中获得的缆芯上,然后缓慢开机,进行绕包;
S8:挤包外护套:在挤塑机料筒中加入低烟无卤聚烯烃,设置机身温度:一区85~90℃,二区105~110℃,三区130~135℃,四区135~140℃,五区135~140℃;设置机头温度:机头六区115~120℃,机脖七区115~120℃,机头八区135~140℃;将S7中获得的缆芯由带张力调节的放线架经导轮装置进入挤塑机模具中进行挤塑,形成柔性防火电缆。
9.根据权利要求8所述的一种柔性防火电缆的制备方法,其特征在于,所述S4中交联参数为:光照强度80~90%,出线速度35~45m/min。
10.根据权利要求8所述的一种柔性防火电缆的制备方法,其特征在于,所述S5中的缆线芯节距为480~560mm。
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