CN117612780A - 一种稀土锌合金耐寒电缆及其制备方法 - Google Patents
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Abstract
本发明涉及电缆技术领域,具体涉及一种稀土锌合金耐寒电缆及其制备方法。本发明的稀土锌合金耐寒电缆由内而外依次为缆芯,无纺布层和特种耐寒料护套层,所述缆芯由三根线芯与填充材料绞合构成,所述线芯为将耐寒绝缘料挤出包裹稀土锌合金导体而成,所述稀土锌合金导体以铝为主材,加入了稀土、锌以及其它微量合金元素,除去了铝中的杂质,细化了铝的晶粒,再加上添加了锌和铝钛碳等新型材料,在保证优异导电性能的情况下,大大提高了导体的力学性能,具有优异的抗腐蚀性能以及耐寒性能,大大降低了综合安装成本,使“以锌代铜”成为现实。
Description
技术领域
本发明涉及电缆技术领域,尤其涉及一种稀土锌合金耐寒电缆及其制备方法。
背景技术
电力传输的主要载体——电线电缆,以往均采用铜、铝作为导体,由于铜资源紧缺,加之铜的价格昂贵,市场上仍然在使用一种铝电缆,由于铝电缆是采用电工用6000系列铝杆进行加工,该产品的一个主要缺点是脆度高,在电缆安装时只要一定角度的扭转,导体容易产生裂纹,裂口就会发热、腐蚀,是出现火灾的重要原因,也是不能被市场广泛应用的一个致命原因,限制了铝电缆的应用。而且在我国的东北、西北、内蒙古等地区,气候寒冷,气温常年大部分时间都在零下40-80℃,将电缆应用在在户外时,电缆绝缘线芯和外护套很容易因为温度过低出现开裂的问题。
中国发明专利CN201210353951.8公开了一种异型耐氧化高导电率铝合金碳纤维导线及制造方法,该方法将异型铝合金单丝和复合碳纤维绞合紧压制成导线,本发明所得的铝合金为新型的Al-Cu-Fe系合金材料,其抗拉强度高,伸长率较高,易于拉制加工,最后制成的导线的电阻率小,伸长率高,但是无法应用于一些低温恶劣环境下,限制了其应用范围。
因此,亟需一种稀土锌合金耐寒电缆,一是针对铝电缆铝电缆脆性高易产生裂纹的问题,二是针对低温情况下,电缆绝缘线芯和外护套开裂的问题。
发明内容
有鉴于此,本发明的目的在于提出一种稀土锌合金耐寒电缆及其制备方法,以解决铝电缆脆性高易产生裂纹和低温下电缆绝缘线芯和外护套开裂的问题。
基于上述目的,本发明提供了一种稀土锌合金耐寒电缆,所述稀土锌合金耐寒电缆由内而外依次为缆芯,无纺布层和特种耐寒料护套层;所述缆芯由三根线芯与填充材料绞合构成;所述线芯为将耐寒绝缘料挤出包裹稀土锌合金导体而成;
所述稀土锌合金导体由以下重量百分比原料组成:0.8%-1.2%的稀土、1%-1.5%的锌、0.05%-0.15%的铜、0.01%-0.05%的锆、0.02%-0.04%的镍、0.01%-0.08%的钛、0.9%-1.2%的铝钛碳、0.1%-0.2%的杂质,余量为铝。
优选地,所述稀土为铈和镧,且其按照任意比例混合而成。
优选地,所述铝块的纯度为3N。
优选地,所述填充材料为多根无尘岩棉绳构成,单根无尘岩棉绳的直径为1.8-2.5mm。
优选地,所述耐寒绝缘料为单层或者三层交联聚乙烯。
优选地,所述特种耐寒护套层由耐低温型聚烯烃护套料挤出而成。
进一步的,本发明还提供一种稀土锌合金耐寒电缆的制备方法,具体制备步骤如下:
(1)将纯度为3N的铝锭放在冶炼炉进行熔化,按照比例加入锌,铜,锆,镍,钛,铝钛碳,稀土和杂质,经过冶炼,精炼后,得到锌合金液;
(2)将锌合金液经过除气后再浇铸成锌合金条,经过轧机轧制形成的稀土锌合金杆;
(3)将圆形拉丝模调整为异形拉丝模,采用十三模拉丝机进行拉丝,拔出异形单丝;
(4)将异形绞丝模在框绞上绞合成圆柱形稀土锌合金异型导体;
(5)将绞合好的圆柱形稀土锌合金导体放入退火罐,退火,冷却,用镀锌机将电镀液镀在导体表面,干燥,得到稀土锌合金导体;
(6)将稀土锌合金导体用耐寒绝缘料包裹形成绝缘线芯,周围放上填充材料,再在成缆机上从内到外依次绕包一层无纺布,再用特种耐寒料挤出外护套,形成稀土锌合金耐寒电缆。
优选地,所述步骤(1)中熔化的温度为750-800℃。
优选地,所述步骤(4)中退火温度为290-310℃,退火时间为9-10h。
优选地,所述电镀液由氧化镍、氧化锌、稀土硝酸盐、多乙烯多胺,去离子水按照质量比80-150:50-150:0.02-1:1-5:500-800混合而成。
本发明的有益效果:
(1)本发明的稀土锌合金耐寒电缆导体在冶炼过程中,添加的稀土,锌和铝钛碳等一系列原料,具有细化晶核的作用,使得其具有较好的防腐蚀性能。
(2)本发明的稀土锌合金耐寒电缆导体,通过电镀的方式在其表面形成一层含有稀土、锌,镍等多元合金膜,进一步提高了其抗腐蚀性能,同时也增强了其机械性能。
(3)本发明的稀土锌合金耐寒电缆,在等效的前提下,比传统的铜缆更适合于大跨度的电力工程中,大大降低了所需的人力物力。
(4)本发明的稀土锌合金耐寒电缆采用特殊电缆材料增强了电缆的绝缘和外护套的耐寒性,大大提高了电缆在低温环境下的耐寒防冻等综合性能。
附图说明
为了更清楚地说明本发明或现有技术中的技术方案,下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍,
图1为本发明实施例2所制备的稀土锌合金耐寒电缆径向截面结构示意图;
图中:稀土锌合金导体圆形单丝1,稀土锌合金导体中间层(异形单丝)2,稀土锌合金导体外层(异形单丝)3,多元合金镀液层4,耐寒绝缘层5,填充材料6,无纺布层7,特种耐寒料护套层8。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚明白,以下结合具体实施例,对本发明进一步详细说明。
实施例1:一种稀土锌合金耐寒电缆的制备方法,具体步骤如下:
(1)将97份纯度为3N的铝锭放入冶炼炉,在750℃下进行熔化保温,随后加入1份锌,0.05份铜,0.01份锆,0.02份镍,0.01份钛,0.9份铝钛碳,0.8-1.2份铈镧混合物和0.1份杂质,经过冶炼,精炼,熔化后,得到锌合金液;
(2)将锌合金液经过除气后再浇铸成锌合金条,经过轧机轧制形成的稀土锌合金杆;
(3)将圆形拉丝模调整为异形拉丝模,采用十三模拉丝机进行拉丝,拔出异形单丝;
(4)将异形绞丝模放在框绞上绞合成圆柱形稀土锌合金异型导体;
(5)将80份氧化镍、50份氧化锌、0.02份稀土硝酸盐、1份多乙烯多胺,500份去离子水混合,充分搅拌,得到电镀液;
(6)将绞合好的圆柱形稀土锌合金异型导体放入退火罐中,在290℃下进行退火,退火时间为9h,冷却,用镀锌机将电镀液镀在导体表面,干燥,得到稀土锌合金导体;
(7)将三层交联聚乙烯共挤在稀土锌合金导体上形成绝缘线芯,周围放上直径为1.8mm无尘岩棉绳,再在成缆机上从内到外依次绕包一层无纺布,再用耐低温型聚烯烃护套料挤出外护套,得到稀土锌合金耐寒电缆。
实施例2:一种稀土锌合金耐寒电缆的制备方法,具体步骤如下:
(1)将96份纯度为3N的铝锭放入冶炼炉,在780℃下进行熔化保温,随后加入1.3份锌,0.1份铜,0.03份锆,0.03份镍,0.05份钛,1.1份铝钛碳,1份铈镧混合物和0.15份杂质,经过冶炼,精炼,熔化后,得到锌合金液;
(2)将锌合金液经过除气后再浇铸成锌合金条,经过轧机轧制形成的稀土锌合金杆;
(3)将圆形拉丝模调整为异形拉丝模,采用十三模拉丝机进行拉丝,拔出异形单丝;
(4)将异形绞丝模放在框绞上绞合成圆柱形稀土锌合金异型导体;
(5)将120份氧化镍、100份氧化锌、0.5份稀土硝酸盐、3份多乙烯多胺,650份去离子水混合,充分搅拌,得到电镀液;
(6)将绞合好的圆柱形稀土锌合金异型导体放入退火罐中,在300℃下进行退火,退火时间为9.5h,冷却,用镀锌机将电镀液镀在导体表面,干燥,得到稀土锌合金导体;
(7)将三层交联聚乙烯共挤在稀土锌合金导体上形成绝缘线芯,周围放上直径为2.2mm无尘岩棉绳,再在成缆机上从内到外依次绕包一层无纺布,再用耐低温型聚烯烃护套料挤出外护套,得到稀土锌合金耐寒电缆。
实施例3:一种稀土锌合金耐寒电缆的制备方法,具体步骤如下:
(1)将95份纯度为3N的铝锭放入冶炼炉,在800℃下进行熔化保温,随后加入1.5份锌,0.15份铜,0.05份锆,0.04份镍,0.08份钛,1.2份铝钛碳,1.2份铈镧混合物和0.2份杂质,经过冶炼,精炼,熔化后,得到锌合金液;
(2)将锌合金液经过除气后再浇铸成锌合金条,经过轧机轧制形成的稀土锌合金杆;
(3)将圆形拉丝模调整为异形拉丝模,采用十三模拉丝机进行拉丝,拔出异形单丝;
(4)将异形绞丝模放在框绞上绞合成圆柱形稀土锌合金异型导体;
(5)将150份氧化镍、150份氧化锌、1份稀土硝酸盐、5份多乙烯多胺,800份去离子水混合,充分搅拌,得到电镀液;
(6)将绞合好的圆柱形稀土锌合金异型导体放入退火罐中,在310℃下进行退火,退火时间为10h,冷却,用镀锌机将电镀液镀在导体表面,干燥,得到稀土锌合金导体;
(7)将三层交联聚乙烯共挤在稀土锌合金导体上形成绝缘线芯,周围放上直径为2.5mm无尘岩棉绳,再在成缆机上从内到外依次绕包一层无纺布,再用耐低温型聚烯烃护套料挤出外护套,得到稀土锌合金耐寒电缆。
对比例1:与实施例2的区别在于:所述导体为纯铜导体。
对比例2:与实施例2的区别在于:所述导体为铝合金导体。
性能测试
延伸性:根据GB/T 5584.2-2020,对实施例和对比例进行测试,测试结果如表1所示;
抗拉强度:根据GB/T5584.2-2020,对实施例和对比例进行测试,测试结果如表1所示;
电气性能:以铜的导电率为100%进行计算,将实施例和对比例的导电率进行计算,结果如表1所示;
屈服强度:根据GB/T 3880.2-2012,对实施例和对比例进行测试,测试结果如表1所示。
表1性能测试结果
延伸率(%) | 抗拉强度(MPa) | 导电率(%) | 屈服强度(MPa) | |
实施例1 | 33 | 116 | 62.2 | 54 |
实施例2 | 34 | 115 | 62.5 | 55 |
实施例3 | 33 | 117 | 62.3 | 54 |
对比例1 | 25 | 220 | 100 | 60 |
对比例2 | 20 | 121 | 60.3 | 45 |
数据分析:通过表中数据能够看出本发明所制备的稀土锌合金耐寒电缆其延伸率与抗蠕变性能能够优于铜缆;抗拉强度虽然只有铜导体的一半,但是由于该稀土锌合金的密度只有铜导体的30%,在同等电气性能的前提下,即使稀土锌合金导体截面积提高到铜导体截面积的150%,稀土锌合金导体的重量也只有铜导体的45%,这使得稀土锌合金导体的抗拉强度相对于铜导体还有一定的优势;在相同载流量前提下,同等长度的稀土锌合金导体的重量仅为铜缆的一半,稀土锌合金导体的导电率约为62.5%,且2单位重量的铜的电阻与1单位质量的稀土锌合金的电阻相同,当合金导体的截面积是铜的1.5倍时,其电气性能相同,电缆的整体重量得到了减少,降低了使用时所耗费的人力物力。
所属领域的普通技术人员应当理解:以上任何实施例的讨论仅为示例性的,并非旨在暗示本发明的范围(包括权利要求)被限于这些例子;在本发明的思路下,以上实施例或者不同实施例中的技术特征之间也可以进行组合,步骤可以以任意顺序实现,并存在如上所述的本发明的不同方面的许多其它变化,为了简明它们没有在细节中提供。
本发明旨在涵盖落入所附权利要求的宽泛范围之内的所有这样的替换、修改和变型。因此,凡在本发明的精神和原则之内,所做的任何省略、修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (10)
1.一种稀土锌合金耐寒电缆,其特征在于,所述稀土锌合金耐寒电缆由内而外依次为缆芯,无纺布层和特种耐寒料护套层;所述缆芯由三根线芯与填充材料绞合构成;所述线芯为将耐寒绝缘料挤出包裹稀土锌合金导体而成;
所述稀土锌合金导体由以下重量百分比原料组成:0.8%-1.2%的稀土、1%-1.5%的锌、0.05%-0.15%的铜、0.01%-0.05%的锆、0.02%-0.04%的镍、0.01%-0.08%的钛、0.9%-1.2%的铝钛碳、0.1%-0.2%的杂质,余量为铝。
2.根据权利要求1所述的一种稀土锌合金耐寒电缆,其特征在于,所述稀土为铈和镧。
3.根据权利要求1所述的一种稀土锌合金耐寒电缆,其特征在于,所述铝的纯度为3N。
4.根据权利要求1所述的一种稀土锌合金耐寒电缆,其特征在于,所述填充材料为多根无尘岩棉绳构成,单根无尘岩棉绳的直径为1.8-2.5mm。
5.根据权利要求1所述的一种稀土锌合金耐寒电缆,其特征在于,所述耐寒绝缘料为单层或者三层交联聚乙烯。
6.根据权利要求1所述的一种稀土锌合金耐寒电缆,其特征在于,所述特种耐寒护套层由耐低温型聚烯烃护套料挤出而成。
7.一种稀土锌合金耐寒电缆的制备方法,其特征在于,具体制备步骤如下:
(1)将纯度为3N的铝锭放在冶炼炉进行熔化,按照比例加入锌,铜,锆,镍,钛,铝钛碳,稀土和杂质,经过冶炼,精炼,熔化后,得到锌合金液;
(2)将锌合金液经过除气后再浇铸成锌合金条,经过轧机轧制形成φ9mm的稀土锌合金杆;
(3)将圆形拉丝模调整为异形拉丝模,采用十三模拉丝机进行拉丝,拔出异形单丝;
(4)将异形绞丝模放在框绞上绞合成圆柱形稀土锌合金异型导体;
(5)将绞合好的圆柱形稀土锌合金异型导体放入退火罐,退火,冷却,用镀锌机将电镀液镀在导体表面,干燥,得到稀土锌合金导体;
(6)将耐寒绝缘料挤出在稀土锌合金导体上形成绝缘线芯,周围放上填充材料,再在成缆机上从内到外依次绕包一层无纺布,再用特种耐寒料挤出外护套,形成稀土锌合金耐寒电缆。
8.根据权利要求7所述的一种稀土锌合金耐寒电缆的制备方法,其特征在于,所述步骤(1)中熔化的温度为750-800℃。
9.根据权利要求7所述的一种稀土锌合金耐寒电缆的制备方法,其特征在于,所述步骤(5)中退火温度为290-310℃,退火时间为9-10h。
10.根据权利要求7所述的一种稀土锌合金耐寒电缆的制备方法,其特征在于,所述电镀液由氧化镍、氧化锌、稀土硝酸盐、多乙烯多胺,去离子水按照质量比80-150:50-150:0.02-1:1-5:500-800混合而成。
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