CN117079872B - 一种绝缘分支电缆及其制备方法 - Google Patents
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Abstract
本发明公开一种绝缘分支电缆及其制备方法,属于特种电缆制备技术领域,包括主电缆和分支电缆,所述主电缆设置有连接处,所述连接处的主导体芯与所述分支电缆的导体芯连接,所述主电缆和分支电缆均设置有外密封管,所述外密封管由绝缘聚烯烃材料制成,按重量份数计,所述绝缘聚烯烃材料包括有如下的组分组成:聚氯乙烯树脂100份、增塑剂12‑22份、抗氧剂1‑3份、润滑剂1‑2份、热稳定剂1‑2份、填料10‑18份、助剂0‑8份;其中,所述润滑剂为固态烷烃蜡与壳聚糖的甲基磷酸改性产物的混合物;本发明所述绝缘聚烯烃材料具有良好的可注塑性。
Description
技术领域
本发明涉及特种电缆制备技术领域,具体涉及一种绝缘分支电缆及其制备方法。
背景技术
预支分支电缆是指由工厂预制成完整连续的成套电缆,在主干电缆规定部位及其要求,将主干电缆和分支电缆的导体,通过铜或铜合金管压缩连接,并进行完整的绝缘处理。预制分支电缆作为配电干线方式应用于城市高层建筑上能使低压配电系统更安全、更可靠、更经济,已获得广泛的推广应用。近年来,随着人类环保和安全意识的提高,无卤低烟阻燃聚烯烃电缆得到了广泛应用并呈现出很大的发展潜力,代表了当今电线电缆的发展趋势。
分支电缆的绝缘材料为聚氯乙烯绝缘和聚乙烯绝缘,而护套材料则为聚氯乙烯护套或聚烯烃护套,由于聚氯乙烯模塑结构比较密实且熔合性能好经高强度密闭处理,能形成良好的气密和防水性能,机械性能和物理性能良好,在分支电缆上应用广泛,但聚氯乙烯电缆料由于含有大量的填充料及无机阻燃剂,挤出(注塑)过程中粘度大,摩擦生热大,流动性差,导致挤出性能不佳。
发明内容
针对上述问题,本发明提供一种绝缘分支电缆及其制备方法。
本发明的目的采用以下技术方案来实现:
一种绝缘分支电缆,包括主电缆和分支电缆,所述主电缆设置有连接处,所述连接处的主导体芯与所述分支电缆的导体芯连接,所述主电缆和分支电缆均设置有外密封管,所述外密封管由绝缘聚烯烃材料制成,按重量份数计,所述绝缘聚烯烃材料包括有如下的组分组成:
聚氯乙烯树脂100份、增塑剂12-22份、抗氧剂1-3份、润滑剂1-4份、热稳定剂1-2份、填料10-18份、助剂0-8份;其中,所述润滑剂为重量比例为1:1的固态烷烃蜡与壳聚糖的甲基磷酸改性产物的混合物,所述固态烷烃蜡的碳原子数为15-50,密度在0.90-0.93g/cm3;所述壳聚糖的甲基磷酸改性产物的制备方法包括以下步骤:
称取甲基磷酸并加入到醇水混合溶剂中,充分混合至溶解完全,加入壳聚糖,搅拌并升温至30-40℃,保温搅拌反应0.5-1h,再升温至50-60℃,并保温搅拌回流反应8-12h,反应完成后减压蒸除溶剂,制得;其中,所述甲基磷酸与所述壳聚糖的重量比例为1:(3.2-3.3)。
在一些优选的实施方式中,所述绝缘聚烯烃材料包括有如下的组分组成:
聚氯乙烯树脂100份、增塑剂14-17份、抗氧剂1-2份、润滑剂2-3份、热稳定剂1.2-1.4份、填料12-15份、助剂0-1份。
在一些优选的实施方式中,所述聚氯乙烯树脂的聚合度在1000-1700。
在一些优选的实施方式中,所述增塑剂为偏苯三酸三辛酯、季戊四醇酯、聚酯增塑剂UN615中的一种或几种。
在一些优选的实施方式中,所述抗氧剂为硫代双酚类化合物;优选为双硫醚。
在一些优选的实施方式中,所述热稳定剂为硬脂酸钙、硬脂酸锌、硬脂酸钡、硬脂酸铅中的一种或几种。
在一些优选的实施方式中,所述填料包括改性二氧化硅或改性鸟粪石,所述改性二氧化硅或改性鸟粪石的制备方法包括以下步骤:
(1)前处理
称取二氧化硅微粉并分散在酸性的过氧化氢水溶液中,搅拌反应过夜,滤出、淋洗、干燥制得表面活化的二氧化硅微粉;或;
称取鸟粪石微粉并分散在碱性的过氧化氢水溶液中,搅拌反应过夜,滤出、淋洗、干燥制得表面活化的鸟粪石微粉;
(2)表面修饰
分别称取4,4'-二羟基联苯、对苯二甲酸、2,6-萘二甲酸、对羟基苯甲酸并溶解在二甲基甲酰胺溶剂中,得到混合溶液,将所述表面活化的二氧化硅微粉或表面活化的鸟粪石微粉分散在所述混合溶液中,充分搅拌混合,在保护气氛下,边搅拌边加入N-(3-羧苯基)-4-苯乙炔基邻苯二甲酰亚胺、乙酸酐和乙酸钾,添加完成后继续在保护气氛下升温至100-120℃并搅拌回流反应1-2h,然后再升温至140-150℃并搅拌回流反应1-2h,反应完成后分离沉淀,洗涤、干燥至恒重,制得表面修饰二氧化硅微粉或表面修饰鸟粪石微粉;
(3)后处理
在真空或保护气氛下,将所述表面修饰二氧化硅微粉或表面修饰鸟粪石微粉以1-2℃/min的速率升温至280-300℃并保温1-2h以稳定化,保温完成后再升温至350℃并保温10-30min,制得所述改性二氧化硅或改性鸟粪石。
在一些优选的实施方式中,所述4,4'-二羟基联苯与所述对苯二甲酸、所述2,6-萘二甲酸、所述对羟基苯甲酸的重量比例为10:(7-7.2):(2.3-2.4):(24-28);所述4,4'-二羟基联苯与所述N-(3-羧苯基)-4-苯乙炔基邻苯二甲酰亚胺、所述乙酸酐、所述乙酸钾的重量比例为10:(11-11.5):(0.9-0.92):(0.06-0.065)。
本发明的另一方面在于提供一种所述绝缘分支电缆的制备方法,具体包括以下步骤:
S1、按比称取各原料,备用;
S2、将所述聚氯乙烯树脂加入到密炼机中,设定混炼温度为120-150℃,待完全熔化后加入所述热稳定剂、所述增塑剂、所述抗氧剂和所述润滑剂,继续混炼10-30min,最后加入所述填料和所述助剂,继续混炼1-10min,采用模塑法或挤塑法成型,冷却后制得。
本发明的有益效果为:
针对现有技术中聚氯乙烯电缆料由于高填充料造成的注塑粘度大、挤出性能不佳的问题,本发明提供一种绝缘分支电缆,其外密封管由绝缘聚烯烃材料制成,所述绝缘聚烯烃材料以聚氯乙烯树脂为基料,通过组分调整获得一种具有良好可注塑性的聚氯乙烯电缆料,具体的,本发明在现有的填料填充和助剂组分的基础上,通过复配润滑剂提高混合树脂料的流动性,降低注塑粘度;进一步的,本发明还通过填料改性进一步提高挤出性能,具体的,本发明在现有的二氧化硅填料的基础上,先通过表面活化引入羟基,再与4,4'-二羟基联苯、对苯二甲酸、2,6-萘二甲酸、对羟基苯甲酸进行共聚酯交换,在所述填料表面修饰共聚酯化产物,表面修饰降低了二氧化硅微球填料的不规则度,提高其球形度,从而降低了填料间、填料与熔体间的摩擦,从而降低粘度;同时还可以提高阻燃性能,降低填料和阻燃助剂的添加量;鸟粪石含氮、磷等阻燃元素,具有良好的阻燃性,将其作为填充填料可以进一步地提高其阻燃性能。
具体实施方式
结合以下实施例对本发明作进一步描述。
实施例1
一种绝缘分支电缆,包括主电缆和分支电缆,所述主电缆设置有连接处,所述连接处的主导体芯与所述分支电缆的导体芯连接,所述主电缆和分支电缆均设置有外密封管,所述外密封管由绝缘聚烯烃材料制成,按重量份数计,所述绝缘聚烯烃材料包括有如下的组分组成:
聚氯乙烯树脂100份、增塑剂14份、抗氧剂1.5份、润滑剂2.5份、热稳定剂1.3份、填料15份;
其中,所述聚氯乙烯树脂的聚合度1500;
所述增塑剂为偏苯三酸三辛酯;
所述抗氧剂为双硫醚;
所述润滑剂为重量比例为1:1的固态烷烃蜡与壳聚糖的甲基磷酸改性产物的混合物,所述固态烷烃蜡的碳原子数在15-50,其中正链烷含量在60-70%,密度在0.90-0.93g/cm3;所述壳聚糖的甲基磷酸改性产物的制备方法包括以下步骤:
称取甲基磷酸并加入到甲醇水混合溶剂中,充分混合至溶解完全,加入壳聚糖,搅拌并升温至35℃,保温搅拌反应1h,再升温至55℃,并保温搅拌回流反应12h,反应完成后减压蒸除溶剂,制得;其中,所述甲基磷酸与所述壳聚糖的重量比例为1:3.2;
所述热稳定剂为钙锌稳定剂;
所述填料为二氧化硅微粉;
所述绝缘分支电缆的制备方法具体包括以下步骤:
S1、按比称取各原料,备用;
S2、将所述聚氯乙烯树脂加入到密炼机中,设定混炼温度为130℃,待完全熔化后加入所述热稳定剂、所述增塑剂、所述抗氧剂和所述润滑剂,继续混炼15min,最后加入所述填料和所述助剂,继续混炼5min,采用模塑法或挤塑法成型,冷却后制得。
实施例2
一种绝缘分支电缆,包括主电缆和分支电缆,所述主电缆设置有连接处,所述连接处的主导体芯与所述分支电缆的导体芯连接,所述主电缆和分支电缆均设置有外密封管,所述外密封管由绝缘聚烯烃材料制成,按重量份数计,所述绝缘聚烯烃材料包括有如下的组分组成:
聚氯乙烯树脂100份、增塑剂14份、抗氧剂1.5份、润滑剂2.5份、热稳定剂1.3份、填料15份;
其中,所述聚氯乙烯树脂、所述增塑剂、所述抗氧剂、所述润滑剂、所述热稳定剂同实施例1,所述填料为改性二氧化硅,所述改性二氧化硅的制备方法包括以下步骤:
(1)前处理
称取二氧化硅微粉并分散在酸性的过氧化氢水溶液中,搅拌反应过夜,滤出、淋洗、干燥制得表面活化的二氧化硅微粉;
(2)表面修饰
分别称取4,4'-二羟基联苯、对苯二甲酸、2,6-萘二甲酸、对羟基苯甲酸并溶解在二甲基甲酰胺溶剂中,得到混合溶液,将所述表面活化的二氧化硅微粉分散在所述混合溶液中,充分搅拌混合,在保护气氛下,边搅拌边加入N-(3-羧苯基)-4-苯乙炔基邻苯二甲酰亚胺、乙酸酐和乙酸钾,添加完成后继续在保护气氛下升温至110℃并搅拌回流反应1.5h,然后再升温至140℃并搅拌回流反应1h,反应完成后分离沉淀,洗涤、干燥至恒重,制得表面修饰二氧化硅微粉;
其中,所述4,4'-二羟基联苯与所述对苯二甲酸、所述2,6-萘二甲酸、所述对羟基苯甲酸的重量比例为10:7.2:2.3:25;所述4,4'-二羟基联苯与所述N-(3-羧苯基)-4-苯乙炔基邻苯二甲酰亚胺、所述乙酸酐、所述乙酸钾的重量比例为10:11.2:0.9:0.062;
(3)后处理
在真空或保护气氛下,将所述表面修饰二氧化硅微粉以2℃/min的速率升温至300℃并保温1h以稳定化,保温完成后再升温至350℃并保温15min,制得所述改性二氧化硅;
所述绝缘分支电缆的制备方法同实施例1。
实施例3
一种绝缘分支电缆,包括主电缆和分支电缆,所述主电缆设置有连接处,所述连接处的主导体芯与所述分支电缆的导体芯连接,所述主电缆和分支电缆均设置有外密封管,所述外密封管由绝缘聚烯烃材料制成,按重量份数计,所述绝缘聚烯烃材料包括有如下的组分组成:
聚氯乙烯树脂100份、增塑剂14份、抗氧剂1.5份、润滑剂2.5份、热稳定剂1.3份、填料15份;
其中,所述聚氯乙烯树脂、所述增塑剂、所述抗氧剂、所述润滑剂、所述热稳定剂同实施例1,所述填料为改性鸟粪石,所述改性鸟粪石的制备方法包括以下步骤:
(1)前处理
称取鸟粪石微粉并分散在碱性的过氧化氢水溶液中,搅拌反应过夜,滤出、淋洗、干燥制得表面活化的鸟粪石微粉;
步骤(2)、(3)同实施例2;
所述绝缘分支电缆的制备方法同实施例1。
对比例
一种绝缘分支电缆,包括主电缆和分支电缆,所述主电缆设置有连接处,所述连接处的主导体芯与所述分支电缆的导体芯连接,所述主电缆和分支电缆均设置有外密封管,所述外密封管由绝缘聚烯烃材料制成,按重量份数计,所述绝缘聚烯烃材料包括有如下的组分组成:
聚氯乙烯树脂100份、增塑剂14份、抗氧剂1.5份、润滑剂2.5份、热稳定剂1.3份、填料15份;
其中,所述聚氯乙烯树脂、所述增塑剂、所述抗氧剂、所述热稳定剂、所述填料同实施例1;
所述润滑剂为固态烷烃蜡,所述固态烷烃蜡同实施例1;
所述绝缘分支电缆的制备方法同实施例1。
实验例
对实施例1-3、对比例所述绝缘聚烯烃材料的流变性能和阻燃性能进行测定,其中,试样的氧指数根据GB/T 2406.1-2008测试;拉伸强度、断裂伸长率根据GB/T 1040.1-2018测试;熔融特性在转矩流变仪上试验;测试结果如表1所示。
表1 实施例1-3、对比例所述绝缘聚烯烃材料的流变性能和阻燃性能
最后应当说明的是,以上实施例仅用以说明本发明的技术方案,而非对本发明保护范围的限制,尽管参照较佳实施例对本发明作了详细地说明,本领域的普通技术人员应当理解,可以对本发明的技术方案进行修改或者等同替换,而不脱离本发明技术方案的实质和范围。
Claims (7)
1.一种绝缘分支电缆,包括主电缆和分支电缆,所述主电缆设置有连接处,所述连接处的主导体芯与所述分支电缆的导体芯连接,所述主电缆和分支电缆均设置有外密封管,其特征在于,所述外密封管由绝缘聚烯烃材料制成,按重量份数计,所述绝缘聚烯烃材料包括有如下的组分组成:
聚氯乙烯树脂100份、增塑剂12-22份、抗氧剂1-3份、润滑剂1-4份、热稳定剂1-2份、填料10-18份、助剂0-8份;其中,所述润滑剂为重量比例为1:1的固态烷烃蜡与壳聚糖的甲基磷酸改性产物的混合物,所述固态烷烃蜡的碳原子数为15-50,密度在0.90-0.93g/cm3;所述壳聚糖的甲基磷酸改性产物的制备方法包括以下步骤:
称取甲基磷酸并加入到醇水混合溶剂中,充分混合至溶解完全,加入壳聚糖,搅拌并升温至30-40℃,保温搅拌反应0.5-1h,再升温至50-60℃,并保温搅拌回流反应8-12h,反应完成后减压蒸除溶剂,制得;其中,所述甲基磷酸与所述壳聚糖的重量比例为1:(3.2-3.3);
所述填料包括改性二氧化硅或改性鸟粪石,所述改性二氧化硅或改性鸟粪石的制备方法包括以下步骤:
(1)前处理
称取二氧化硅微粉并分散在酸性的过氧化氢水溶液中,搅拌反应过夜,滤出、淋洗、干燥制得表面活化的二氧化硅微粉;或;
称取鸟粪石微粉并分散在碱性的过氧化氢水溶液中,搅拌反应过夜,滤出、淋洗、干燥制得表面活化的鸟粪石微粉;
(2)表面修饰
分别称取4,4'-二羟基联苯、对苯二甲酸、2,6-萘二甲酸、对羟基苯甲酸并溶解在二甲基甲酰胺溶剂中,得到混合溶液,将所述表面活化的二氧化硅微粉或表面活化的鸟粪石微粉分散在所述混合溶液中,充分搅拌混合,在保护气氛下,边搅拌边加入N-(3-羧苯基)-4-苯乙炔基邻苯二甲酰亚胺、乙酸酐和乙酸钾,添加完成后继续在保护气氛下升温至100-120℃并搅拌回流反应1-2h,然后再升温至140-150℃并搅拌回流反应1-2h,反应完成后分离沉淀,洗涤、干燥至恒重,制得表面修饰二氧化硅微粉或表面修饰鸟粪石微粉;
(3)后处理
在真空或保护气氛下,将所述表面修饰二氧化硅微粉或表面修饰鸟粪石微粉以1-2℃/min的速率升温至280-300℃并保温1-2h以稳定化,保温完成后再升温至350℃并保温10-30min,制得所述改性二氧化硅或改性鸟粪石;
所述4,4'-二羟基联苯与所述对苯二甲酸、所述2,6-萘二甲酸、所述对羟基苯甲酸的重量比例为10:(7-7.2):(2.3-2.4):(24-28);所述4,4'-二羟基联苯与所述N-(3-羧苯基)-4-苯乙炔基邻苯二甲酰亚胺、所述乙酸酐、所述乙酸钾的重量比例为10:(11-11.5):(0.9-0.92):(0.06-0.065)。
2.根据权利要求1所述的一种绝缘分支电缆,其特征在于,所述绝缘聚烯烃材料包括有如下的组分组成:
聚氯乙烯树脂100份、增塑剂14-17份、抗氧剂1-2份、润滑剂2-3份、热稳定剂1.2-1.4份、填料12-15份、助剂0-1份。
3.根据权利要求1所述的一种绝缘分支电缆,其特征在于,所述聚氯乙烯树脂的聚合度在1000-1700。
4.根据权利要求1所述的一种绝缘分支电缆,其特征在于,所述增塑剂为偏苯三酸三辛酯、季戊四醇酯、聚酯增塑剂UN615中的一种或几种。
5.根据权利要求1所述的一种绝缘分支电缆,其特征在于,所述抗氧剂为硫代双酚类化合物。
6.根据权利要求1所述的一种绝缘分支电缆,其特征在于,所述热稳定剂为硬脂酸钙、硬脂酸锌、硬脂酸钡、硬脂酸铅中的一种或几种。
7.根据权利要求1-6之一所述的一种绝缘分支电缆的制备方法,其特征在于,包括以下步骤:
S1、按比称取各原料,备用;
S2、将所述聚氯乙烯树脂加入到密炼机中,设定混炼温度为120-150℃,待完全熔化后加入所述热稳定剂、所述增塑剂、所述抗氧剂和所述润滑剂,继续混炼10-30min,最后加入所述填料和所述助剂,继续混炼1-10min,采用模塑法或挤塑法成型,冷却后制得。
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