CN117133503A - High-voltage XLPE (cross-linked polyethylene) insulated power cable and preparation method thereof - Google Patents
High-voltage XLPE (cross-linked polyethylene) insulated power cable and preparation method thereof Download PDFInfo
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- CN117133503A CN117133503A CN202210557715.1A CN202210557715A CN117133503A CN 117133503 A CN117133503 A CN 117133503A CN 202210557715 A CN202210557715 A CN 202210557715A CN 117133503 A CN117133503 A CN 117133503A
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- 238000004513 sizing Methods 0.000 claims abstract description 22
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- 238000009413 insulation Methods 0.000 claims abstract description 20
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 18
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Classifications
-
- H—ELECTRICITY
- 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
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/187—Sheaths comprising extruded non-metallic layers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- 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
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- 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
- H01B13/30—Drying; Impregnating
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
- H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
- H01B3/441—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from alkenes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
- H01B5/16—Non-insulated conductors or conductive bodies characterised by their form comprising conductive material in insulating or poorly conductive material, e.g. conductive rubber
-
- H—ELECTRICITY
- 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
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
-
- H—ELECTRICITY
- 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
- H01B7/2806—Protection against damage caused by corrosion
-
- H—ELECTRICITY
- 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
- H01B7/2825—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable using a water impermeable sheath
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
- Y02A30/14—Extreme weather resilient electric power supply systems, e.g. strengthening power lines or underground power cables
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Insulated Conductors (AREA)
Abstract
The invention discloses a high-voltage XLPE insulated power cable and a preparation method thereof, which are applicable to cables with voltage levels of 66-220 kV; the insulated power cable includes: the insulation wire core sequentially comprises a conductor wire core, a conductor shielding layer, an XLPE main insulation layer and an insulation shielding layer, wherein the conductor shielding layer is coated on the conductor wire core; the semiconductive buffer waterproof layer is arranged outside the insulating shielding layer and is formed by a semiconductive buffer waterproof tape; the composite armor layer is arranged outside the semiconductive buffer waterproof layer, and the smooth inner surface of the composite armor layer extrudes the insulating shielding layer so as to eliminate an air gap between layers; the composite armor layer is made of carbon fiber-thermoplastic resin composite material, and the carbon fiber and the thermoplastic resin are integrally manufactured and formed by adopting a continuous melting-presoaking process under the action of a sizing agent. The invention can effectively eliminate the air gap between the corrugated metal sheath and the water-blocking layer, thereby avoiding the partial discharge of the cable caused by the suspension potential generated between the corrugated metal sheath and the insulating shielding layer and effectively prolonging the service life of the cable.
Description
Technical Field
The invention relates to the technical field of power cables, in particular to a high-voltage XLPE insulated power cable suitable for 66-220 kV voltage class and a preparation method of the cable.
Background
At present, with the transformation of social energy, the power load of enterprises shows an ascending trend, the safety requirements of power supply and transmission systems are also improved, and the consequences of power cables are extremely serious if accidents occur. In conventional power cable structures, metal armor layers are typically provided to increase the mechanical strength of the cable, improve corrosion resistance, improve short circuit current thermal stability, achieve shielding protection, and extend the useful life of the cable. At present, the electric power construction in China is in the gold stage, but the research and development of the high-voltage long-distance power transmission and distribution cable in China are late, and the mature design experience is lacking. Among the standard cables currently used, a single-core cable of 66kV and above is generally a corrugated aluminum sheath crosslinked polyethylene single-core cable (crosslinked polyethylene cable, cross Linked Polyethylene, XLPE), and the total length of the cabling is accumulated to exceed 50000 km.
The single-core cable is generally applied to a continuous extrusion aluminum sheath process or a corrugated aluminum sheath process, and the corrugated aluminum sheath process gradually replaces the continuous extrusion aluminum sheath process along with the development of a welding process. However, the corrugated aluminum sheath is made of metal material, cannot be integrally formed, and needs to be assembled to the cable through welding, and the internal cable structure is damaged by the high temperature generated by the welding process, so that the inner surface of the aluminum sheath needs to be designed into a corrugated shape to avoid the damage of the welding process to the internal structure. In addition, the metal material has a higher thermal expansion coefficient, the sectional area can be changed under the action of thermal expansion and cold contraction, and a gap is reserved for reserving a margin space for thermal expansion. Due to the special geometry of the corrugated aluminum sheath and the thermal expansion and contraction characteristics of metal, an air gap is reserved between the insulating shielding layer and the semiconductive water-resistant layer in the cable, so that a suspension potential is generated between the corrugated aluminum sheath and the insulating shielding layer, and a potential difference is generated between the metal sheath and the insulating shielding layer to cause a partial discharge phenomenon. Although the discharge amount is small, the long-term discharge still damages the main insulation of the cable, even causes breakdown of the cable, and causes safety accidents.
Chinese patent application CN103345965a discloses a 500kV extra-high voltage resistance hydroelectric power cable, comprising from inside to outside: the conductor in the center is sequentially extruded and wrapped with a semiconductive nylon belt, a semiconductive shielding layer, an insulating layer and an insulating layer outside the conductor, and the insulating shielding layer is sequentially wrapped with a semiconductive buffer waterproof layer, an anti-corrosion asphalt layer and an outer sheath outside the insulating shielding layer; a seamless wrinkled metal sleeve is extruded between the semiconductive buffer waterproof layer and the anti-corrosion asphalt layer. The semi-conductive buffering waterproof layer, the anti-corrosion asphalt layer and the seamless corrugated metal sheath in the coating layer can effectively realize radial waterproof, but an air gap exists between the corrugated metal sheath and the waterproof layer, so that the cable partial discharge is caused by the influence of the suspension potential generated between the corrugated metal sheath and the insulating shielding layer, and the service life of the cable is influenced.
Therefore, there is a need for a high voltage XLPE insulated power cable that effectively eliminates the air gap between the corrugated metal sheath and the water blocking layer, and avoids the partial discharge of the cable caused by the floating potential generated between the corrugated metal sheath and the insulating shielding layer.
The information disclosed in this background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person of ordinary skill in the art.
Disclosure of Invention
The invention aims to provide a high-voltage XLPE insulated power cable suitable for 66-220 kV voltage level and a preparation method of the cable, which can effectively eliminate an air gap between a corrugated metal sheath and a water blocking layer, further avoid partial discharge of the cable caused by suspension potential generated between the corrugated metal sheath and an insulating shielding layer and effectively prolong the service life of the cable.
To achieve the above object, according to a first aspect of the present invention, there is provided a high voltage XLPE insulated power cable, the high voltage being of the order of 66-220 kV; comprising the following steps: the insulation wire core sequentially comprises a conductor wire core, a conductor shielding layer, an XLPE main insulation layer and an insulation shielding layer, wherein the conductor shielding layer is coated on the conductor wire core; the semiconductive buffer waterproof layer is arranged outside the insulating shielding layer and is formed by a semiconductive buffer waterproof tape; the composite armor layer is arranged outside the semiconductive buffer waterproof layer, and the smooth inner surface of the composite armor layer extrudes the insulating shielding layer so as to eliminate an air gap between layers; the composite armor layer is made of carbon fiber-thermoplastic resin composite material, and the carbon fiber and the thermoplastic resin are integrally manufactured and formed by adopting a continuous melting-presoaking process under the action of a sizing agent.
Further, in the above technical scheme, the outside of the composite armor layer is also provided with an outer sheath layer and a graphite coating in sequence, and all layers of the cable are tightly attached.
Further, in the above technical solution, the thermoplastic resin may be polypropylene resin.
Furthermore, in the above technical scheme, the conductor core can be made of industrial pure copper material and is formed by stacking and combining five conductors, insulating oilpaper is arranged between each two adjacent conductors, and the cross section shape of the conductors can be fan-shaped.
Furthermore, in the above technical scheme, the conductor shielding layer can be made of aluminum foil mylar material which is formed by taking aluminum foil as a base material and attaching the aluminum foil to the polyester tape after back glue, and is used for eliminating the potential difference inside the conductor core.
In the technical scheme, the XLPE main insulating layer can be made of crosslinked polyethylene material, and the crosslinked polyethylene is a crosslinked polymer generated by polyethylene under the actions of radiation irradiation and a crosslinking agent.
Further, in the above technical solution, the insulating shielding layer may be made of an aluminum foil mylar material, so that the insulating shielding layer is equipotential with the XLPE main insulating layer to be shielded.
Further, in the above technical scheme, the semiconductive buffer water-blocking tape of the semiconductive buffer water-blocking layer may comprise a three-layer structure of semiconductive polyester fiber nonwoven fabric, copper wire woven mesh and semiconductive expansion water-absorbing cotton, which are combined together by a hot pressing manner for water blocking, moisture proofing and balancing the potential difference between the insulating shielding layer and the composite armor layer.
Furthermore, in the technical scheme, the outer sheath layer can be made of polyvinyl chloride materials and uniformly extruded on the outer surface of the composite armor layer.
Further, in the above technical scheme, the graphite coating can be coated on the outer surface of the outer sheath layer for carrying out alternating current withstand voltage test on the outer sheath.
According to a second aspect of the invention, the invention provides a method for preparing a high-voltage XLPE insulated power cable, which comprises the steps of sequentially preparing an insulated wire core, a semiconductive buffer waterproof layer, a composite armor layer, an outer sheath layer and a graphite coating from inside to outside, wherein the preparation of the composite armor layer comprises the following steps: A. sizing the carbon fiber tows, removing burrs to enable the carbon fibers to be smooth and flat, and drying the sized tows twice; B. weaving the sized carbon fiber tows into carbon fiber narrow bands through a three-dimensional weaving process; C. impregnating the flat narrow band with resin, and drying the narrow band after full impregnation; D. and tightly winding the dried narrow band on the outer surface of the semiconductive buffer waterproof layer to form the composite armor layer.
In the above technical solution, the sizing treatment in the step a may use a polyurethane or epoxy resin sizing agent, and the sizing treatment may specifically include: a1, carrying out wiredrawing treatment on carbon fiber tows and covering the carbon fiber tows by using a sizing agent; a2, pre-drying the sized tows at the temperature of 100-150 ℃ for 10-60S to obtain tows with the water content of less than 1%; a3, carrying out secondary drying on the pre-dried tows, wherein the secondary drying temperature is 100-250 ℃, and the duration time is 30-60S, so as to obtain tows with the water content of less than 0.1%.
Further, in the above technical solution, the resin impregnation in the step C may include: c1, mixing the polypropylene resin in a molten state, a curing agent and a release agent according to the following formula 1:2: mixing thoroughly in a ratio of 0.5, and adding into a dipping tank; and C2, drying the narrow band fully soaked by the resin at the drying temperature of 60-120 ℃ for 5-12 hours.
Further, in the above technical solution, the thickness of the composite armor layer prepared in the step D may be 3mm.
Further, in the above technical solution, the preparation of the outer sheath layer may specifically be: uniformly extruding polyvinyl chloride on the surface of the composite armor layer to form an outer sheath layer, wherein the thickness of the outer sheath layer can be calculated by adopting the following formula:
t=0.035d+1.0 formula (1);
wherein T is the nominal thickness of the outer sheath, and mm; d is the diameter of the cable before the sheath is extruded, and mm.
Compared with the prior art, the invention has the following beneficial effects:
1) According to the high-voltage XLPE insulated power cable, the composite armor layer is replaced by the existing corrugated aluminum sheath, the carbon fiber resin-based composite material has high strength-high toughness, the surface is flat and smooth, and the air gap caused by the special geometric structure of the existing corrugated metal sheath and the thermal expansion and contraction characteristics of metal is thoroughly eliminated, so that the suspension potential generated between the metal armor layer and the insulating shielding layer can be effectively avoided, and further, the cable breakdown accident caused by the partial discharge phenomenon generated by main insulation is avoided;
2) The composite armor layer can be tightly attached to the adjacent cladding layer, so that the flexibility of the cable is increased, and the cable is more convenient to bend and lay; the composite armor layer also has good high temperature resistance, corrosion resistance, waterproof performance and mechanical performance, so that damage to the cable due to mechanical external force can be effectively avoided when the cable is buried, and meanwhile, the flame retardant capacity, corrosion resistance and water blocking capacity of the cable are improved, and the service life of the cable is greatly prolonged.
The foregoing description is only an overview of the present invention, and it is to be understood that it is intended to provide a more clear understanding of the technical means of the present invention and to enable the technical means to be carried out in accordance with the contents of the specification, while at the same time providing a more complete understanding of the above and other objects, features and advantages of the present invention, and one or more preferred embodiments thereof are set forth below, together with the detailed description given below, along with the accompanying drawings.
Drawings
Fig. 1 is a schematic longitudinal sectional view of the high voltage XLPE insulated power cable of the present invention.
Fig. 2 is a schematic illustration of the split form of the conductor core of the high voltage XLPE insulated power cable of the present invention.
Fig. 3 is a schematic diagram of a composite armor layer preparation flow in the preparation method of the high-voltage XLPE insulated power cable of the present invention.
The main reference numerals illustrate:
the cable comprises a 1-conductor wire core, a 2-conductor shielding layer, a 3-XLPE main insulator, a 4-insulating shielding layer, a 5-semiconductive buffer waterproof layer, a 6-composite armor layer, a 7-outer sheath layer and an 8-graphite coating.
Detailed Description
The following detailed description of embodiments of the invention is, therefore, to be taken in conjunction with the accompanying drawings, and it is to be understood that the scope of the invention is not limited to the specific embodiments.
Throughout the specification and claims, unless explicitly stated otherwise, the term "comprise" or variations thereof such as "comprises" or "comprising", etc. will be understood to include the stated element or component without excluding other elements or other components.
Spatially relative terms, such as "below," "beneath," "lower," "above," "upper," and the like, may be used herein for ease of description to describe one element's or feature's relationship to another element's or feature's in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the article in use or operation in addition to the orientation depicted in the figures. For example, if the article in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the elements or features. Thus, the exemplary term "below" may encompass both a direction of below and a direction of above. The article may have other orientations (rotated 90 degrees or other orientations) and the spatially relative descriptors used herein interpreted accordingly.
The terms "first," "second," and the like herein are used for distinguishing between two different elements or regions and are not intended to limit a particular position or relative relationship. In other words, in some embodiments, the terms "first," "second," etc. may also be interchanged with one another.
The inventors have found that: in the currently used high-voltage XLPE single-core cable, the armor layer generally uses a metal corrugated aluminum sheath (namely, the armor layer made of metal, the inner surface is corrugated), so that an air gap exists between the metal armor layer and the insulating shielding layer of the cable and the water-blocking layer, and further, a suspension potential is generated between the metal armor layer and the insulating shielding layer, further, the partial discharge can be caused by the potential difference existing between the metal armor layer and the insulating shielding layer, the insulating layer of the cable can be damaged even if the discharge capacity is weak, even the cable breaks down, and the cable fault is caused. Based on the above research, the invention provides an improved high-voltage XLPE insulated power cable and a preparation method thereof.
Example 1
As shown in fig. 1, the present embodiment provides a high voltage XLPE insulated power cable suitable for a voltage class of 66 to 220kV, comprising: conductor core 1 and parcel conductor core 1 just set up from inside to outside conductor shielding layer 2, XLPE main insulating layer 3, insulating shielding layer 4, semiconductive buffer water-resisting layer 5, compound armor 6, outer restrictive coating 7 and graphite coating 8 in proper order.
As further shown in fig. 1, the conductor core 1 at the center, the conductor shielding layer 2, XLPE main insulating layer 3 and insulating shielding layer 4 which are coated on the conductor and sequentially arranged outwards form an insulating core, and the insulating core is a main insulating structure of the power cable, that is, the main structure of the cable, and can be regarded as a whole. The conductor core 1 can be made of industrial pure copper, specifically, the copper content is not lower than 99.5%, so that the skin effect and line loss of the conductor can be effectively reduced, the flexibility of the conductor core is improved, and meanwhile, the heating is reduced. The conductor core 1 is formed by stacking and combining five conductors (refer to fig. 2), insulating oilpaper is arranged between every two adjacent conductors, the cross section of each conductor is fan-shaped, namely the conductor core 1 adopts a five-equal-part split conductor structure, and the structure can effectively reduce the increase of alternating current resistance caused by skin effect and reduce heat generation. The conductor shielding layer 2 can be made of aluminum foil mylar material which is formed by taking aluminum foil as a base material and laminating the aluminum foil and the polyester tape after back glue, and is used for eliminating potential difference inside a conductor wire core, so that the electric field inside the conductor is distributed more uniformly, the increase of the electric field intensity on the surface of the conductor caused by the non-smoothness of the surface of the conductor is eliminated, and the conductor shielding layer 2 and the shielded conductor wire core 1 are equipotential. The XLPE main insulation layer 3 may be made of a cross-linked polyethylene material, which is a cross-linked polymer formed by polyethylene under the irradiation of radiation and the action of a cross-linking agent, and the layer plays a main role of electrical insulation. Specifically, the crosslinked polymer produced by Polyethylene (PE) under the radiation irradiation and the action of the crosslinking agent has good high temperature resistance and insulating property, can be used for 40 years at the temperature of 85 ℃ for a long time, has high strength and rigidity, can maintain the insulation wire core structure not to deform greatly, and can resist the damage of mechanical external force. The insulating and shielding layer 4 may be made of an aluminum foil mylar material for equipotential the insulating and shielding layer 4 with the XLPE main insulating layer 3 to be shielded. Specifically, the insulating shield layer 4 can make the electric field distribution inside the conductor more uniform, and eliminate the increase in electric field intensity on the surface of the conductor caused by the non-smoothness of the surface of the conductor, similar to the effect of the conductor shield layer 2.
As further shown in fig. 1, a semiconductive buffer water-blocking layer 5 is provided outside the insulating shield layer 4 and is constituted by a semiconductive buffer water-blocking tape. The semi-conductive buffering water-blocking layer 5 has the functions of water blocking and moisture proofing, can balance the potential difference between the insulating shielding layer 4 and the composite armor layer 6, ensures the equipotential of the insulating shielding layer 4 and the composite armor layer 6, can release short-circuit current when a cable has a short-circuit fault, and has the functions of water blocking, mechanical damping, heat buffering, metal shielding and electric field homogenization. The structure of the semiconductor water-resistant belt comprises: the semi-conductive polyester fiber non-woven fabric, the copper wire woven net (the copper wire diameter is about 0.5 mm) and the semi-conductive expansion absorbent cotton are combined together in a hot pressing mode, and are tightly wrapped on the outer surface of the cable insulation shielding layer 4 to form a semi-conductive buffer waterproof layer 5, wherein the thickness of the layer can be set to be about 1.5 mm.
As further shown in fig. 1, the composite armor layer 6 is disposed outside the semiconductive buffer water-resistant layer 5 and has a smooth inner surface capable of pressing the insulating shield layer 4, thereby eliminating an air gap between the layers. The composite armor layer 6 of the embodiment is made of a carbon fiber-thermoplastic resin composite material, and the carbon fiber and the thermoplastic resin are integrally manufactured and formed by adopting a continuous melting-presoaking process under the action of a sizing agent. The carbon fiber-thermoplastic resin composite material may specifically be a carbon fiber-polypropylene resin composite material. Compared with the corrugated aluminum sheath applied to the metal armor layer of the existing high-voltage single-core power cable, the carbon fiber resin-based composite material is a chopped strip, can be directly wound (metal welding is avoided), is tightly coated on the outer surface of the cable (namely the outer surface of the semiconductive buffer water-resistant layer 5), and avoids the generation of an air gap, so that the suspension potential possibly generated between the composite armor layer 6 and the insulation shielding layer 4 and the semiconductive buffer water-resistant layer 5 is fundamentally avoided. Meanwhile, the surface of the composite armor layer 6 is smooth and flat, and the phenomenon of concentrated discharge caused by uneven surface of the existing metal armor layer is avoided. Based on this, the composite armor layer 6 of the invention ensures that the equipotential is kept with the insulating shielding layer 4, compared with the existing corrugated aluminum sheath layer, the cable electric field homogenizing effect is better, the air gap is completely eliminated, meanwhile, the uneven structure at the corrugated aluminum corrugation is avoided, the whole electric field of the cable is more uniform, and the partial discharge phenomenon caused by the potential difference generated between the existing metal aluminum sheath and the insulating shielding layer is avoided. Preferably, but not by way of limitation, the carbon fibers in the composite armor 6 composite are preferably T500 continuously reinforced carbon fiber tapes, and the thermoplastic resin may be formed from polypropylene resin as described above, both of which are formed by a continuous melt-prepreg process under the action of a sizing agent. The composite material has ultrahigh unidirectional tensile strength and elastic modulus, low density (weight reduction), excellent corrosion resistance, flame retardance, flexibility and excellent damping and antimagnetic performance, so that the invention can greatly improve the mechanical external damage resistance, flame retardance, water resistance, corrosion resistance and laying bending ability of the power cable, and can effectively improve the service reliability and service life of the high-voltage XLPE insulated power cable.
As further shown in fig. 1, the outer sheath layer 7 and the graphite coating layer 8 of the present embodiment are sequentially disposed outside the composite armor layer 6, and preferably, but not limited to, the outer sheath layer 7 may be made of a polyvinyl chloride material and uniformly extruded on the outer surface of the composite armor layer 6. The graphite coating 8 is coated on the outer surface of the outer sheath layer 7 and is used for carrying out alternating current withstand voltage test on the outer sheath. Eight layers of the cable are tightly attached.
The composite armor layer of the high-voltage XLPE insulated power cable replaces the existing corrugated aluminum sheath, the carbon fiber resin-based composite material used by the high-voltage XLPE insulated power cable has high strength-high toughness, and the surface is flat and smooth, so that air gaps caused by the special geometric structure of the corrugated metal sheath and the thermal expansion and contraction characteristics of metal are thoroughly eliminated, and therefore, the suspended potential generated between the metal armor layer and the insulated shielding layer can be effectively avoided, and further, cable breakdown accidents caused by partial discharge phenomenon generated by main insulation are avoided; the composite armor layer can be tightly attached to the adjacent cladding layer, so that the flexibility of the cable is increased, and the cable is more convenient to bend and lay; the composite armor layer has good high temperature resistance, corrosion resistance and waterproof performance, so that damage to the cable due to mechanical external force can be effectively avoided when the cable is buried and laid, and meanwhile, the flame retardant capacity, corrosion resistance and water blocking capacity of the cable are improved, and the service life of the cable is greatly prolonged.
Example 2
The embodiment provides a preparation method of a high-voltage XLPE insulated power cable, which comprises the steps of sequentially preparing an insulated wire core, a semiconductive buffer water-resistant layer, a composite armor layer, an outer sheath layer and a graphite coating from inside to outside, and preparing each layer of the insulated wire core (namely a conductor wire core 1, a conductor shielding layer 2 wrapping the conductor wire core 1, an XLPE main insulating layer 3 and an insulated shielding layer 4) and the semiconductive buffer water-resistant layer 5 as follows: the conductor wire core 1 is formed by stranding and shaping industrial pure copper after being drawn by a drawing machine to form a fan-shaped wire core (refer to figure 2) with a preset cross section area and a central angle of 72 DEG, five groups of wire cores are respectively separated by insulating oil paper and stacked together to form the conductor wire core 1, and the diameter of the wire core can be determined according to the actual service working condition parameters of the cable; the conductor shielding layer 2 takes aluminum foil as a base material, and an aluminum foil Mylar material formed by gluing a polyester tape is tightly adhered to the conductor wire core 1, wherein the polyester material can be PET, and the thickness of the conductor shielding layer 2 can be set to be about 0.1 mm; the XLPE main insulating layer 3 can be extruded by an extruder to form a solid insulating layer, the polyethylene PE material is extruded to the outer surface of the cable, and the cross-linked polyethylene insulating layer (namely the main insulating layer 3) is formed by cross-linking by irradiation, and the thickness of the cross-linked polyethylene insulating layer can be determined according to the actual service working condition parameters of the cable; the preparation method of the insulating shielding layer 4 and the conductor shielding layer 2 is consistent, namely, aluminum foil mylar material is tightly attached on the XLPE main insulating layer 3 to form the layer; the semiconductive water-blocking layer 5 is composed of a semiconductive water-blocking tape, and its structure comprises: the semi-conductive polyester fiber non-woven fabric, the copper wire woven net (the diameter of the copper wire is about 0.5 mm), the semi-conductive expansion absorbent cotton and the three-layer structure are combined together in a hot pressing mode, and are tightly wrapped on the outer surface of the insulating shielding layer 4 of the cable to form a semi-conductive waterproof layer 5, and the thickness of the layer is about 1.5 mm.
Next, this embodiment focuses on the process of preparing the composite armor layer 6, as shown in fig. 3, where the preparation of the composite armor layer includes the following steps:
and step S101, sizing the carbon fiber tows, removing burrs to enable the carbon fibers to be smooth and flat, and drying the sized tows twice. Specifically:
first, carbon fiber tows are subjected to a drawing treatment and covered with a sizing agent so that each tow is uniformly covered with the sizing agent. In the embodiment, the large tows (48K) of the T500 carbon fibers can be adopted for sizing treatment, and sizing agents such as polyurethane or epoxy resin are used for carrying out surface treatment on the carbon fibers, so that the aim of improving the narrow-band interface performance of the carbon fibers is achieved, the deburring is improved, the carbon fibers are smooth and flat, and the pretreatment is carried out for the subsequent dipping step.
And secondly, drawing the carbon fiber tows, introducing the drawn carbon fiber tows into a drying roller for pre-drying, wherein the temperature of the pre-drying roller can be set to be 100-150 ℃ and the duration time is 10-60S, so that the carbon fiber tows with the water content less than 1% can be obtained.
And then, carrying out secondary drying on the pre-dried tows, wherein the temperature in a secondary drying roller can be set to be 100-250 ℃, and the duration is 30-60S, so that the carbon fiber tows with the water content less than 0.1% can be obtained.
Step S102, weaving the carbon fiber tows subjected to the sizing treatment in the step S101 into carbon fiber narrow bands through a three-dimensional weaving process. Specifically, the narrow band width of the formed carbon fiber was 60mm.
In step S103, the flat narrow band is impregnated with resin, and after sufficient impregnation, the narrow band is dried. Specifically, the carbon fiber narrow band woven in the step S102 is led out and sent to a resin impregnation unit, the guide device keeps the carbon fiber narrow band straight from the shaft bracket to the die, and constant tension is applied to the carbon fiber narrow band to avoid deformation of the carbon fiber narrow band. In the impregnation operation, first, a polypropylene resin (PP) in a molten state, a curing agent and a releasing agent are mixed according to 1:2: mixing thoroughly in a ratio of 0.5, and adding into a dipping tank; and then the carbon fiber narrow belt is pulled at a constant speed to pass through an impregnating tank, so that the carbon fiber narrow belt is fully impregnated with resin and then dried. In the embodiment, the impregnated carbon fiber narrow band is dried once, the temperature of a drying box can be set to be 60-120 ℃, and the drying time can be 5-12 hours.
Step S104, tightly winding the narrow band dried in the step S103 on the outer surface of the semiconductive buffer water-resistant layer 5 to form a composite armor layer 6, wherein the thickness of the composite armor layer 6 is about 3mm.
Further, after the preparation of the composite armor layer 6, the preparation of the outer sheath layer 7 is performed, and the preparation of the layer specifically comprises: polyvinyl chloride is evenly extruded on the surface of the composite armor layer 6 to form an outer sheath layer, and the thickness of the outer sheath layer 7 can be calculated by adopting the following formula:
t=0.035d+1.0 formula (1);
wherein T is the nominal thickness of the outer sheath, and mm; d is the diameter of the cable before the sheath is extruded, and mm.
Finally, the graphite coating is uniformly applied to the cable surface to form the graphite coating 8.
With the manufacturing method of the present embodiment, the insulated power cable of embodiment 1 can be obtained, thereby achieving the technical effect of embodiment 1.
The foregoing descriptions of specific exemplary embodiments of the present invention are presented for purposes of illustration and description. It is not intended to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiments were chosen and described in order to explain the specific principles of the invention and its practical application to thereby enable one skilled in the art to make and utilize the invention in various exemplary embodiments and with various modifications as are suited to the particular use contemplated. Any simple modifications, equivalent variations and modifications of the above-described exemplary embodiments should fall within the scope of the present invention.
Claims (15)
1. The high-voltage XLPE insulated power cable is characterized in that the high voltage is 66-220 kV voltage class; comprising the following steps:
the insulation wire core sequentially comprises a conductor wire core, a conductor shielding layer, an XLPE main insulation layer and an insulation shielding layer, wherein the conductor shielding layer, the XLPE main insulation layer and the insulation shielding layer are coated on the conductor wire core from inside to outside;
the semiconductive buffer waterproof layer is arranged outside the insulating shielding layer and is formed by a semiconductive buffer waterproof belt;
the composite armor layer is arranged outside the semiconductive buffer waterproof layer, and the smooth inner surface of the composite armor layer extrudes the insulating shielding layer so as to eliminate an air gap between layers; the composite armor layer is made of carbon fiber-thermoplastic resin composite material, and the carbon fiber and the thermoplastic resin are integrally manufactured and formed by adopting a continuous melting-presoaking process under the action of a sizing agent.
2. The high-voltage XLPE insulated power cable of claim 1, wherein the composite armor layer is further provided with an outer jacket layer and a graphite coating layer in sequence, and each layer of the cable is tightly attached.
3. The high voltage XLPE insulated power cable of claim 1, wherein the thermoplastic resin is a polypropylene resin.
4. The high-voltage XLPE insulated power cable of claim 1, wherein the conductor core is made of industrial pure copper, and is formed by stacking and combining five conductors, and insulating oilpaper is arranged between each two adjacent conductors, and the cross section shape of the conductors is a sector.
5. The high-voltage XLPE insulated power cable of claim 1, wherein the conductor shielding layer is made of aluminum foil mylar material which is formed by attaching aluminum foil to a polyester tape after back-gluing, and is used for eliminating potential difference inside the conductor core.
6. The high voltage XLPE insulated power cable of claim 1, wherein the XLPE main insulation layer is made of a cross-linked polyethylene material, the cross-linked polyethylene being a cross-linked polymer formed by radiation irradiation of polyethylene and a cross-linking agent.
7. The high voltage XLPE insulated power cable of claim 1, wherein the insulating shield layer is of aluminum foil mylar material for equipotential the insulating shield layer with the XLPE main insulation layer being shielded.
8. The high voltage XLPE insulated power cable of claim 1, wherein the semiconductive buffer water-blocking tape of the semiconductive buffer water-blocking layer comprises a three-layer structure of semiconductive polyester fiber nonwoven fabric, copper wire woven mesh and semiconductive expansion water-absorbing cotton, which are bonded together by hot pressing for water-blocking and moisture-blocking and balancing the potential difference between the insulating shield layer and the composite armor layer.
9. The high voltage XLPE insulated power cable of claim 2, wherein the outer jacket layer is of polyvinyl chloride material and is uniformly extruded over the outer surface of the composite armor layer.
10. The high voltage XLPE insulated power cable of claim 2, wherein the graphite coating is applied to an outer surface of the outer jacket layer for ac withstand voltage testing of the outer jacket.
11. The preparation method of the high-voltage XLPE insulated power cable is characterized by comprising the steps of sequentially preparing an insulated wire core, a semiconductive buffer waterproof layer, a composite armor layer, an outer sheath layer and a graphite coating from inside to outside, wherein the preparation of the composite armor layer comprises the following steps:
A. sizing the carbon fiber tows, removing burrs to enable the carbon fibers to be smooth and flat, and drying the sized tows twice;
B. weaving the carbon fiber tows subjected to sizing treatment into carbon fiber narrow bands through a three-dimensional weaving process;
C. impregnating the flat narrow band with resin, and drying the narrow band after the narrow band is fully impregnated;
D. and tightly winding the dried narrow band on the outer surface of the semiconductive buffer water-resistant layer to form the composite armor layer.
12. The method for preparing a high voltage XLPE insulated power cable according to claim 11, wherein the sizing treatment in the step a uses a polyurethane or epoxy resin sizing agent, and the sizing treatment specifically comprises:
a1, carrying out wiredrawing treatment on the carbon fiber tows and covering the carbon fiber tows by using the sizing agent;
a2, pre-drying the sized tows at the temperature of 100-150 ℃ for 10-60S to obtain tows with the water content of less than 1%;
a3, carrying out secondary drying on the pre-dried tows, wherein the secondary drying temperature is 100-250 ℃, and the duration time is 30-60S, so as to obtain tows with the water content of less than 0.1%.
13. The method of preparing a high voltage XLPE insulated power cable of claim 11, wherein the resin impregnation in step C comprises:
c1, mixing the polypropylene resin in a molten state, a curing agent and a release agent according to the following formula 1:2: mixing thoroughly in a ratio of 0.5, and adding into a dipping tank;
and C2, drying the narrow band fully soaked by the resin at the drying temperature of 60-120 ℃ for 5-12 hours.
14. The method of producing a high voltage XLPE insulated power cable of claim 11, wherein the composite armor layer produced in step D has a thickness of 3mm.
15. The method for preparing a high voltage XLPE insulated power cable according to claim 11, wherein the preparation of the outer sheath layer is specifically: uniformly extruding polyvinyl chloride on the surface of the composite armor layer to form an outer sheath layer, wherein the thickness of the outer sheath layer is calculated by adopting the following formula:
t=0.035d+1.0 formula (1);
wherein T is the nominal thickness of the outer sheath, and mm; d is the diameter of the cable before the sheath is extruded, and mm.
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| CN202210557715.1A CN117133503A (en) | 2022-05-19 | 2022-05-19 | High-voltage XLPE (cross-linked polyethylene) insulated power cable and preparation method thereof |
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| CN202210557715.1A CN117133503A (en) | 2022-05-19 | 2022-05-19 | High-voltage XLPE (cross-linked polyethylene) insulated power cable and preparation method thereof |
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