CN1220024A - 多层加强稳定型的电缆结构 - Google Patents

多层加强稳定型的电缆结构 Download PDF

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Publication number
CN1220024A
CN1220024A CN97194859A CN97194859A CN1220024A CN 1220024 A CN1220024 A CN 1220024A CN 97194859 A CN97194859 A CN 97194859A CN 97194859 A CN97194859 A CN 97194859A CN 1220024 A CN1220024 A CN 1220024A
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China
Prior art keywords
cable
layer
construction
fiber
reinforced
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CN97194859A
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CN1088900C (zh
Inventor
贾斯·拉维拉
马克库·T·苏范托
威萨·图纳恩
马克库·赫诺
乔瑞·贾维克
卡瑞·柯贾维恩
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Nokia Kaapeli Oy
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Nokia Kaapeli Oy
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Priority claimed from FI961822A external-priority patent/FI106005B/fi
Priority claimed from FI964989A external-priority patent/FI105391B/fi
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Publication of CN1220024A publication Critical patent/CN1220024A/zh
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    • B29C44/22—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length consisting of at least two parts of chemically or physically different materials, e.g. having different densities
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
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Abstract

本发明涉及一种多层的加强稳定型电缆结构,它包括一个芯部(1,11)和一个非金属护套部分,该护套部分具有一些阻挡和保护层以及两个或多个加强层。为了控制电缆的机械性质和阻挡性质,借助于纤维加强或分层阻挡、以不同的角度、按可控方式来定向阻挡和保护层和/或加强层(12、13)。

Description

多层加强稳定型的电缆结构
本发明涉及多层加强稳定型的电缆结构，它包括一个芯部和一个非金属护套部分，该护套部分具有阻挡保护层以及两个或多个加强层。
就各种电缆而论，例如光缆，上述类型的电缆结构当前是众所周知的。现有的非金属光缆结构需要几个处理步骤，其中的某些步骤可能是极其缓慢的。分别加到电缆结构上的那些昂贵的加强部分需要使用附加的措施，以获得较好的夹紧或防水性能，这进一步延长了制造过程。为了改善电缆结构的热稳定性，即减小热压缩，通常还必须使用杆状加强件。使用这种加强件使得电缆产生某些不一定总是有积极作用的性质：弯曲刚度、较大的尺寸、高的价格、等。在所谓的中央管道结构中使用这样的一些分开的组合加强杆尤其困难，其中的加强杆必须安装在芯的外周边，并且出于对称性的理由至少必须有两个加强杆。
如果电缆要具备抗啮齿类动物和白蚁的机械保护、以及抗油和化学物质作用的能力，和/或具有抗潮湿和气体的阻挡能力，就必须使用昂贵的半成品产品，它们必须分开处理加工，并且这通常是复杂的工艺步骤。这就使结构复杂化，并且增加了产品的成本。
本发明的目的是提供一种能够克服现有技术的上述缺点的电缆结构。此目的由本发明的电缆结构实现。本发明的电缆结构的特征在于，为了控制电缆的机械性质和阻挡性质，就借助于纤维加强件或分层阻挡层、以不同的角度，按可控的方式来定向阻挡和保护层和/或加强层。
和现有技术相比，本发明的一个优点例如是，可以按照需要很便利地调节电缆的机械性质和阻挡性质。这是因为，本发明是简单的，制造可以在一个挤压步骤中完成，因而成本低。本发明的另一个优点是，有可能提供可再次熔化的结构，因此完全可以回收重复利用。
下面，借助于用附图说明的实例更详细地描述本发明，其中：
图1是现有技术电缆结构的总图；
图2是现有技术电缆护套的总体剖面图；
图3-6表示本发明的光缆结构的实例；以及
图7表示设有一个金属芯的本发明的电缆的实例。
图1是现有技术的一种电缆结构的总图。在图1中，用标号1-2表示一个芯部。该芯部例如可由光纤1和二次涂层2组成。标号3和4表示由护套形成的层。杆状加强件由标号5代表。出于对称性的考虑，要有两个杆状加强件5，它们安装在电缆的外周边，如上所述。
图1的电缆结构一般是通过在二次涂层2上挤压功能层产生的。在图1的实例中，用标号3-4表示功能层。挤压操作一般是由一个普通十字头喷嘴完成的。这种技术的缺点之一是在各个层中形成的熔合线。熔合线对电缆的性质有不利的影响，因为它们在层中引起断点，而在这些断点处的层的性质是和层的其它点的层的性质不相同的。在图2中可以看见这些断点，图2表示的是一个电缆结构的剖面图。在图2中用箭头N表示断点。
因此，本发明涉及一种能够克服上述现有技术缺点的电缆结构。按照本发明的基本构思，为了控制电缆的机械性质和阻挡性质，重要的应该是，借助于纤维加强层和分层阻挡层，以不同的角度并按可控的方式来定向阻挡和保护层和/或加强层。本发明的电缆的特征包括：具有典型的非金属电缆的抗拉强度、在宽的温度范围内和温度突变的条件下的尺寸稳定性、以及结构的硬度和柔性。本发明的另一特征是，可在一个挤压步骤中以可控的方式制造出多层结构。
在电缆芯的上部、或在相应的所谓二次护套上挤压出来的并用于稳定电缆结构的加强层例如由一种热塑性材料，例如：聚烯烃、聚酯、聚酰胺、或类似物组成，其中用固定的加强纤维加强，例如用玻璃纤维、碳纤维、硼纤维、芳族聚酰胺的纤维、或者相应的纤维加强。另外，加强层也可以由正温性的主链液晶聚合物(LCP)制成，或者由这样一种聚合物再加上一种常规的热塑性材料组成的一种混合物制成。除了常用的一些热塑性材料外，凡在挤压期间或挤压之后易于定向和/或交联的热塑性材料全都是特别优先选用的。这种类型的液晶塑料在熔化状态容易流动，因此可按和热塑性材料相同的方式进行处理。基于该材料典型的内部组织结构，当熔化的材料冷却时就在原地形成了复合的、类似纤维的结构。因此在挤压过程期间，发生液晶聚合物的纤维分离。在专利申请PCT/FI96/00261和FI964988中公开了一种极力推荐的，在此过程中用于获得径向取向的螺钉状的几何布局。在液晶塑料或其混合物的情况下，在处理期间最好是追求高的预拉伸比，以产生高的分离纤维程度。因此，最好提供尽可能多的薄LCP加强层，而不用一个或两个较厚的LCP加强层。在这种情况下，可保持预拉伸比很高，并且在整个层中都能有效地发生分离纤维的作用。
某些加强层可由通过连续的纤维加强了的热塑性组合物形成。在这些实施例中，用完全连续的玻璃纤维、或聚芳基酰胺纤维、或者相应的纤维去浸渍一种常用的热塑性材料或者粘结塑料。定向的PE和PP纤维具有极好的强度性质；它们为此目的使用受到了相当低的晶体熔点的限制。由于熔点低，在处理期间要求的高的挤压温度破坏了在纤维中提供的取向和强度。已经令人惊奇地发现，甚至用相当低的辐射强度，也能交联定向的PE纤维，使这种定向更加耐久；因此，使纤维在不损失超过其原始强度的一半的条件下承受加热的时间变得较长，这是很关键的。另外，还可能使用一开始就已交联的、并且只是在此之后才按纤维定向的那些材料。还可以使用在化学上交联的聚乙烯。除了价格方面的优点以外，定向交联的纤维结构还有一个突出的机械方面的优点。已经意外地发现，在此过程中，纤维的表面部分地软化了，并且粘结到周围的基质塑料上，而它的机械强度却仍保持在一个高的水平。对于例如聚芳基酰胺纤维极其难以实现的这样一种良好的粘结性，在执行其它任务时可以保证有良好的冲击强度。此外，纯的聚乙烯结构可保证有好的电性能。对于本发明的优选电缆结构，通过用连续的纤维在线浸渍塑料基质，就可以把这样一种加强层的制造与实际的电缆挤压操作结合起来。在光缆结构中，上述加强层可形成一个保护光纤的第二护套。
如以上所述，本发明的一个主要特征是，每个加强层、保护层、或阻挡层的纤维相对于电缆的纵轴具有某种可控的扭曲定向角。在图3中概括地表示出本发明的一个实施例。在图3中用标号1和11表示芯部。用标号12和13表示设在芯部上部的并且提供加强作用的层。标号14指示护套的表面层。在图3中清晰地表示出层12和13中的加强纤维的不同的定向角。
在所有层中或者在某些层中，纤维的扭曲方向可以平行，但定向角不同。因此，能够以可控的方式调节每一层的抗拉性和柔性。在最靠近电缆中央的层中，即第一加强层中，最好使用基本上平行于电缆纵轴的纤维，即定向角小的纤维。例如，借助于一个扭曲的心轴，如在专利申请FI964989中公开的那样让纤维通过心轴，就可实现纤维的扭曲。可把一个相应的扭曲心轴与在专利申请PCT/FI96/00261中公开的加工方案结合起来，从而除得到连续的纤维外还实现了极其有效的扭曲分子定向。在这种情况下，由于距中心的距离短，故纤维加强层尽可能多地提高了电缆的抗拉强度，同时尽可能少地降低了电缆的柔性，即具有最小可能的变硬效应。因此，为使纤维能把电缆的柔性减小到一个较小程度并且把电缆的径向抗压强度提高到一个较大程度，在外部加强和保护层中的纤维的定向角最好是较大的角度。在图3中表示出这样一种安排。此外，若在外层中纤维的定向角较大，则可提高防啮齿类动物的保护效果。
以不同角度定向的、在横向方向本身是松脆的、并且具有低抗拉强度的纤维加强层是彼此之间相互加强的，这是因为不同层的不平行的纤维一旦受到横向应力作用就是相互支撑的。因此，由按可控方式定向的纤维组成的多层分层结构就形成了一种网络结构，其中，通过调节和控制不同层中纤维的定向角可控制整个加强层的机械性质。
保护电缆芯的所谓阻挡层可阻止湿气、甚至于可能阻止氢气穿透而进入电缆芯。这样一层最好可以包括：正温性的主链液晶聚合物(LCP)、聚烯烃(主要是高密度的聚乙烯HDPE或聚丙烯PP)、环烯共聚物(COC)、或具有良好湿气阻挡性质的对应热塑料材料。在本发明的没有熔合线的对称结构中，用一个极薄的上述塑料层来实现此阻挡性质。典型的层厚度约为50-100m，视材料而定。对称的均匀结构可保证：当电缆遭遇机械应力时，即使是一个很薄的层，在机械方面也是足够地强，依然不致损伤并且可保持其可操作性。特别是当阻挡材料是液晶塑料时，只用一层(分层结构)就可实现所需的加强功能，即抗拉和抗压强度。另一方面，在分开的加强层中使用液晶塑料和热塑材料的混合物，使LCP纤维或薄片层的定向方向相互交叉，这样作不仅可提供优异的机械性质，而且还可提供湿气阻挡性质。在图4中示出了这样一个实施例。在图4中，用标号21表示芯部。由标号22和23表示由LCP纤维或薄片提供的层。由标号24代表表面层。图4清晰地表现出LCP纤维或薄片的交叉定向的方向。由于可以使用的液晶塑料的化学成分完全是芳香族的，并且这些液晶塑料在固态时形成一种严格有序的结构，因此它们即使对于较小的气体分子也能提供特别好的保护作用。尤其是，对于光纤来说，提供防氢的保护层极其重要；在非金属结构中，通过液晶塑料提供这样一种保护层。
在由许多不同的热塑性材料组成的一种多层结构中，功能层(即，阻挡层、加强层、等等)之间的粘结是特别重要的。在本发明的结构中，如果有必要，可在较厚功能层之间形成薄的粘结层。由于粘结塑料是软的，所以重要的是要保持它们的粘结层尽可能地薄。极力推荐的是包括一个功能侧的粘结层。例如，一个半导体粘结层可对安装于其中的光缆提供电保护。无熔合线的对称结构，使具有薄的均匀层成为可能。对于本发明的电缆结构，可以通过各种薄的粘结或缓冲层，调节不同加强层之间的粘结程度，借此可按需要或增加或减小层间的相互作用大小。还可以把改善粘性或弹性的组分本身混入加强层中。另一替换方案是，在同一加强层内的各个纤维段和沿周边方向有较大弹性的各个聚合物段互相交错，从而可在纵向的加强作用和柔性之间实现良好的平衡。在图5中表示出这样一种实施例。在图5中，标号1和31表示芯部。标号32表示一个加强层，把它分为纤维加强段32a和较大弹性的填充物部分32b。标号33代表电缆的表面层。在又一个实施例中，通过一种泡沫聚合物形成该弹性部分或分开的缓冲层，该泡沫聚合物与纤维加强层直接接触，以控制电缆的柔性和抗压性。这样一层一般由密度为50-200kg/cm3的泡沫聚烯烃形成。
如上所述，最好用一个挤压步骤来制造本发明的结构，从而就可以不再需要诸如卷取之类的中间步骤。此外，极其重要的是，熔化材料的流动方向要平行于电缆芯，并且熔化的质量流要在任何阶段都不产生分支，从而就可避免形成所谓的熔合线。一般公知的是，在塑料产品中，熔合线通常是开始断裂的结构弱点。熔合线要显著弱于产品的其它部分。一个均匀的质量流可以形成无缝的均匀层，从而可用比通常需要的层还要薄的层来实现期望的性质。因为在加强和阻挡层中使用的最好的聚合物是相当昂贵的，这是众所周知的，所以较小的材料消耗的经济效益是显著的。因此，本发明使制造在技术上和经济上都优于现有技术结构的多层电缆结构成为可能。
在原理上，可以使用包括旋转的喷嘴设备在内的常规的十字头喷嘴来制造本发明的多层结构。但是在实践中，使用这种技术以可控方式制造多层结构是极其困难的。最好使用例如由EP0422042B1中公开的一种所谓锥形挤压机来制造无熔合线的本发明的多层结构。
虽然以上主要借助于光缆的各个实施例描述了本发明，但应说明的是，本发明还可以应用在芯部由金属导体构成的电缆的情况。
下面，给出按本发明实施的解决方案的几个说明性的例子。所示的例子是四层结构，但显然的是，层数还可以不同，视多层挤压机的结构而定；如果有必要，甚至可以多于四层。这些层是从最里向最外数的。
A．一种独立的光缆芯(PBT、光纤、凝胶)，或一种金属导体，在其上方挤压出多层结构(功能部分和外部护套)。1．-粘结塑料
-LCP或LCP混合物，+45°定向(加强部分)
-LCP或LCP混合物，-45°定向(加强部分)
-外护套(如，PE)正中间的层一起形成了一个阻挡层。2．-粘结塑料
-LCP,LCP混合物或纤维复合材料，+45°定向
-LCP或LCP混合物，薄片层(阻挡层)
-外部护套(如，PE)第一LCP层或类似层是实际的加强层。
特殊结构(连续纤维用作加强层，经在线熔化浸渍)
-如有必要，在紧接共挤压步骤之前用-熔化泵在一个PBT管上方涂一层粘结塑料(热熔的)。1．-在线浸渍的连续的玻璃纤维，该纤维以一适当角度装在一个PBT管周围
-聚烯烃用作基质(可包含功能化的聚烯烃，夹紧)
-或者，粘结塑料用作基质(在两个表面上都要很好夹紧)
-HDPE、COC、LCP、或PO、LCP混合物的均匀薄层(阻挡层)
-粘结塑料
-外部护套(如，PE)2．(-粘结塑料)
-薄LCP或LCP混合物层(湿气阻挡层)
-在线浸渍的连续的玻璃纤维，该纤维以一适当角度装在一个PBT管(聚烯烃用作基质)周围
(-粘结塑料)
-外部护套(聚烯烃)
B．在同一步骤中进行的二次涂敷1．-LCP混合物或纤维复合材料(包括光纤、凝胶)用作保护材料41
-加强结构(轴向定向)
-薄的粘结层42
-实际的加强层(LCP或纤维复合材料，倾斜定向)43
-外部护套(如，PE)44该实施例示于图6中。标号41-44示于图6。2．-热塑性材料(包括光纤、凝胶)用作保护材料
-乙烯/丙烯共聚物(适当的凝胶)或PBT
-或者：COC(同时用于湿气阻挡)
-薄的粘结层
-实际的加强层(PO/纤维或者PO/LCP混合物)，倾斜定向
-外部护套(如，PE)
C．只有多层护套结构，芯部螺旋空间，扭曲结构或金属导线1．-粘结塑料
-中间护套PE
-粘结塑料
-外护套PA12(例如，白蚁保护，抗磨损)2．防火护套
-粘结塑料
-阻挡层(HDPE、COC、LCP或PO/LCP混合物)和/或加强层(参见上述)
-粘结塑料(不是必需的)
-HFFR混合物3．抗啮齿类动物护套
-粘结塑料52
-聚烯烃/玻璃纤维53
-聚烯烃/大量的玻璃纤维(人造纤维或者在线浸渍的连续纤维)54。大的横向定向角。
-薄的HDPE或PA12表面层55。
在图7中表示出上述的实施例。标号51表示一个芯部，芯部51由金属导线组成。标号52-55代表上述各层。标号52-55也被表示在以上例子的对于有关层的描述中。
上述实施例的意图不是以任何方式限制本发明，而在所附的权利要求书的范围之内可以完全自由地修改本发明。因此，显然，本发明的电缆结构或者它的细节不必和附图所示精确地一样，其它的解决方案也是可能的。

Claims (18)

1．一种多层加强稳定型的电缆结构，它包括一个芯部(1,11,21,31,41,51)和一个非金属护套部分，所述护套部分具有一些阻挡及保护层以及两个或多个加强层，其特征在于，为了控制电缆的机械性质和阻挡性质，借助于纤维加强或分层阻挡、以不同的角度、按可控的方式来定向阻挡和保护层、和/或加强层(12、13、22、23、32、53、54)。
2．如权利要求1的电缆结构，其特征在于：加强层是由用短或长纤维加强的热塑性材料制成的。
3．如权利要求2的电缆结构，其特征在于：加强材料是玻璃纤维、碳纤维、硼纤维、或聚芳基酰胺纤维。
4．如权利要求1的电缆结构，其特征在于：在构成加强层的材料中至少一部分是液晶材料。
5．如权利要求1或2的电缆结构，其特征在于：人造纤维或连续纤维是被交联到超过5％凝胶含量的定向聚烯烃。
6．如权利要求5的电缆结构，其特征在于：把加强用的纤维熔合到基质上，使纤维和基质之间的粘结能量大于基质的强度。
7．如前述权利要求1-6中任何一个所述的电缆结构，其特征在于：为了调节抗拉强度和柔性，把每个加强层分成多个片段状部分，其中的硬的加强部分(32a)和弹性较大的填充物部分(32b)相间交错。
8．如前述权利要求1-8中任何一个所述的电缆结构，其特征在于：弹性填充物部分或分开的缓冲层由泡沫聚合物制成。
9．如权利要求1的电缆结构，其特征在于：阻挡层由其中至少有一部分是液晶塑料的材料制成。
10．如前述权利要求1-9中任何一个所述的电缆结构，其特征在于：改善粘结性能的粘结层(42)设在各层之间。
11．如权利要求10的电缆结构，其特征在于：阻挡和粘结层以及加强层是无熔合线的薄的对称层。
12．如权利要求11的电缆结构，其特征在于：各个层是通过挤压过程制造出来的。
13．如权利要求1的电缆结构，其特征在于：至少有一个加强层是由一种复合材料制成的，这种复合材料是由连续纤维加强的，并且包括一种常规的热塑性材料或粘结塑料基质。
14．如权利要求1-13中任何一个所述的电缆结构，其特征在于：在最靠近电缆中心的层(12)中，加强纤维基本上沿电缆的纵向方向放置；而在外部的层(13)中，加强纤维基本上沿圆周方向定向。
15．如前述权利要求1-14中任何一个所述的电缆结构，其特征在于：芯部(11,21,31)由光纤形成。
16．如权利要求15的电缆结构，其特征在于：设置包围光纤并且保护光纤的层，以形成第一加强和/或阻挡层。
17．如前述权利要求1-14中任何一个所述的电缆结构，其特征在于：芯部(51)是由金属导线形成的。
18．如前述权利要求中任何一个所述的电缆结构，其特征在于：至少一部分基质或纤维是交联的。
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