CN1240094C - 熔丝管及其制造技术 - Google Patents
熔丝管及其制造技术 Download PDFInfo
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Abstract
电弧猝熄组分包含一填充剂、一种纤维和一胶合剂。填充剂最好含有一种如蜜胺的电弧猝熄化合物。胶合剂含有一种热固树脂促使电弧猝熄组分在电弧猝熄熔丝管中形成。在较佳设计中,在电弧猝熄熔丝管上还有一外管以使熔丝管整体具高强度。同时在较佳设计中,为了使熔丝管可在一极宽的电流范围内工作,电弧猝熄内管包含一锥形小孔。根据一种制造工艺,外管在内管凝固前形成于电弧猝熄内管上从而成为单一结构。
Description
技术领域
本发明一般涉及电弧猝熄组分和由此形成的物质,尤其涉及利用廉价的材料而容易制造的熔丝管构造。它显示极佳的强度和电弧猝熄参数,可在大范围的电流上工作。
背景技术
在其熔丝管内发生断路的中高压熔断器中的熔丝管需要有高的强度及电弧猝熄参数。以前的熔丝管范例可见于美国专利3,911,385,3,979,709,3,984,800,4,313,100,4,349,803,4,373,555,4,373,556,4,564,830,4,808,963,5,015,514及5,119,060。用于切断大范围电流(如100-10,000安培)的熔丝管尤其需要难以获得的高的强度和电弧猝熄参数。在配电系统中使用的传统的熔断器,其熔丝管的制造是将一细丝缠绕的环氧玻璃外管绕在一硬化纤维内管上,从而达到电弧猝熄参数。还有建议用各种方法制造具有整体高强度和具适当电弧猝熄参数小孔的熔丝管。其中包括利用由环氧树脂混合物支持的纤维来制成一具有电弧猝熄参数的内层,在其之上形成一提供强度的外层的各种生产工艺。在上述专利4,373,555和4,373,556中,熔丝管的电弧猝熄内层是用聚酯纤维和环氧树脂混合物制成。在专利5,015,514中,大约55-60%的三水合铝按其重量与有机纤维和环氧树脂一起包含在一电弧猝熄内层中。在上述专利号4,349,803中,一模压管包括一层可渗漏玻璃纤维织物,其内层是有电弧猝熄材料的热固材料,以及围绕中间可渗漏玻璃纤维织物所形成的外层抗气候部分。
虽然现有技术总体上能用来制造熔断器的熔丝管,但其或者要使用相对较贵的自然资源,或包含复杂的加工和生产过程。并且,大部分无法提供既能承受大电流断路的压力同时能切断低电流故障的熔丝管。
发明内容
因此,本发明的目的是提供可用其制成产品的一电弧猝熄组分,尤其是高强度层熔丝管的电弧猝熄内层。
本发明的另一个目的是为熔断器提供这样一种熔丝管,其显示极佳的强度和电弧猝熄特征,同时可以很容易地用树脂、纤维和填充剂材料制成。
本发明的另外一个目的是提供这样一种熔丝管,其制造是在内管上形成拥有电弧猝熄参数的小孔,在内管凝固前在其之上形成一外管,内外管凝结成单一结构,避免两者之间形成任何电介质接合点或界面。
本发明还有一个目的是为熔丝管提供一电弧猝熄孔,能通过孔内电弧猝熄化合物和孔内预先确定的锥体的结合来切断大范围的电流。
本发明的这些和其他目的是通过提供包括一填充剂、一种纤维和一胶合剂的电弧猝熄组分来有效实现。填充剂最好包括一电弧猝熄化合物,例如蜜胺。胶合物包括一热固树脂使电弧猝熄化合物形成一电弧猝熄熔丝管。最好在电弧猝熄熔丝管上形成一外管,以提供一种整体高强度的熔丝管。为提供一种能在极宽的电流范围内工作的熔丝管,电弧猝熄内管最好含有一锥形小孔。根据一种制造工艺,在内管凝固前在电弧猝熄内管上形成外管,从而形成单一结构。
本发明的组成、操作方法以及本发明的其他目的和优点可通过参照说明书并结合附图而得以更好的理解:
附图说明
图1是根据本发明的一电弧猝熄管的透视图;
图2是根据本发明的一分层熔丝管的透视图;
图3和图4是图1、图2所示熔丝管管壁截面的放大图;
图5是图1、图2所示熔丝管的较佳实施例的放大截面图,显示熔丝管小孔内的锥体。
具体实施方式
已发现电弧猝熄组分可被出乎意料地用来形成熔丝管的内层,例如通过长丝缠绕、注入模压或例如外压的挤压过程,同时显示改善的电弧猝熄特性,电弧猝熄组分包含一纤维、一填充剂和一胶合剂,如热固树脂。填充剂最好包含一种电弧猝熄化合物,例如密鞍。其他填充剂也包括在特定的实施例中。电弧猝熄化合物也可被视为一种电弧猝熄材料或混合物。尽管制造的这种熔丝管可满足某些用途,但为制造需同时为管中所产生的大范围弧形电流提供适当的电弧猝熄孔设计特点的高强度熔丝管,已意外地发现可通过在电弧猝熄组分的内层上覆盖一层高强度的增强性纤维来提供这种高强度熔丝管。对需提供极宽范围电弧猝熄参数(包括在中等电压上极高电流)的熔丝管,电弧猝熄内层形成一锥体,使得熔丝管的排出口空间较大一些,以缓和因极高电流产生大量气体而在孔内逐渐形成的气体停滞。在一较佳实施例中提供了一种倾斜度较缓的锥体,其结构为阶梯状的平底锥口。
尽管根据本发明所制造的产品可利用各种传统的挤压、缠绕、注入模压和其他工艺流程来进行生产,作为本发明的一种更好的形式,熔丝管通过一种长丝缠绕流程进行生产。根据本发明的重要方而,为制成高强度的熔丝管而使用了一种分层长丝缠绕流程,其中一高强度层缠绕在一电弧猝熄内层或内管上。或者,电弧猝熄内层也可通过长丝缠绕来进行制造,外层在电弧猝熄内层上模压而成。在其他实施例中,电弧猝熄内层通过注入模压或外压形成,外层通过长丝缠绕或一过压流程(over-moldingprocess)在内层上形成。在电弧猝熄内层通过注入模压或挤压流程而形成的工艺方法中,纤维的形态是断裂且较短的,而不是适于缠绕制造的长丝形态。
为在大范围电流,包括大电流上达到电弧猝熄性能的最佳点,电弧猝熄内层的小孔呈锥形或阶梯状的平底锥口形,以缓和高电流时的气体停滞。在这方面并根据本发明的重要方而,电弧猝熄层具有预定的纤维分布的均匀性以及填充剂和胶合剂的混合,从而使电弧猝熄层的外表面具有预定的均匀性而使进入电弧猝熄层小孔内的锥度达到最大,即,尽量降低该层的厚度并利用其最大空间而不将小孔暴露于高强度外层或增加内层的厚度。对电弧猝熄层直径的任何不必要的增加是不可取的,因为熔丝管的整体强度会因此而降低。锥体在生产时或之后通过机械加工而形成。同样,外层也有一预定的分布均匀性以达到所要求的均匀性。
根据本发明的其他重要方面,电弧猝熄化合物和小孔中锥体数量之间的关系在大范围的电流上提供了最佳性能。在电弧猝熄化合物数量和小孔锥度之间发现存在一通常的关系,使低电流性能提高并且低电流范围通过一相对较高比例的电弧猝熄化合物而扩大,大电流性能提高并且大电流范围通过增加小孔锥体数量而扩大。也就是说,需要足够数量的电弧猝熄化合物以及预定的胶合剂及纤维来达到低电流性能,从而产生足够的猝熄气体。并且在电弧猝熄层内有足够数量的电弧猝熄材料时,大电流最佳性能通过小孔内相对较大锥体来实现,从而使高电流时产生的大量气体不会停滞。通过由电弧猝熄内层所确立的电弧猝熄特征,形成熔丝管的外层以达到整个熔丝管的高强度。举例说,一较佳实施例的外层使用了一种例如由环氧树脂支持的玻璃纤维的高强度纤维来达到高强度。
现在考虑一下本发明的一个说明性实施例的制造,提供一具有电弧猝熄孔的高强度熔丝管在很宽的电流范围内,如100安培至10,000安培,切断电流,一种凝固剂、一种包含电弧猝熄化合物的填充剂、一热固树脂以及一促进剂(accelerator)被适当地组合并混合。在这一混合体(也可视为一种基体)中,蜜胺被用来作为电弧猝熄化合物,蜜胺按其重量所占组分的比例约为10%-30%,根据欲达到的特定参数而定,在下文中将有详细解释。形态为长丝或丝股的纤维经混合体拉制并绕在覆盖脱模剂的心轴上,经过一圈或多圈缠绕以完成预定厚度的内层。纤维的释放和缠绕速度经设定而使单股的纤维丝平展,在内层的每次缠绕时不会在心轴上重叠。并且,缠绕张力经设定以达到所要求的缠绕内层中混合体及纤维之间的关系。电弧猝熄内层经缠绕相对最终所需的直径要大一些,以容纳因外层缠绕张力所造成的压力。然后外层即刻覆盖在绕线的电弧猝熄内层上,也经过一圈或多圈缠绕以完成预定厚度的外层。缠绕张力经设定而使内层不被过分挤压而挤出太多的混合物。但还是要利用足够的张力使内层外围不致过大而造成整个熔丝管的强度可能降低。然后,熔丝管例如在大约华氏300度经热固。在一可于大幅度范围内切断电流的高强度熔丝管的较佳实施例中,所设计制造的内层组分按重量比例包含约25%的纤维,约20%的蜜胺及大约55%带凝固剂的热固树脂。特定实施例中的熔丝管经过缠绕过程或经适当机械加工(如平底锥口或类似加工)凝固后形成一锥形小孔。
在内管的一个说明性实施例中,纤维是一种如丙烯酸丝的有机纤维。其他合适的纤维包括聚酯、尼龙、人造丝、棉、纤维素及其混合物。内管纤维最好是以丝线、布、纱罩或带的形式而非颗粒或单独的纤维材料。说明性实施例的电弧猝熄化合物是蜜胺。其他合适的化合物包括如特氟隆的氟聚合物、硼酸、三水合铝、氢氧化镁、硅、聚酯、聚氨酯、硼酸锌、苯胍胺、二硫氰尿酰胺(dithioammelide)、氰尿二酰胺、氰尿酰卤化物及其混合物。说明性实施例的热固树脂是双酚-A环氧树脂,合适的热固树脂还包括环脂族环氧树脂及双酚-A和环脂族环氧树脂、酚醛塑料、聚氨酯、聚酯、硅或脲醛的混合物。但已发现在内外层均使用双酚-A环氧树脂有利于避免任何结构性问题。在一特定实施例中,发现BDMA是一种合适的促进剂,Lindride32是一种合适的酸酐凝固剂。同时也发现例如Bentone的悬浮助剂对避免树脂和电弧猝熄化合物之混合物的任何凝固问题很有帮助。虽然本发明的实践中不要求达到所需的电弧猝熄参数和熔丝管的强度,也还是可以在特定的实施例中使用其他填充剂,如二氧化硅、水合氧化铝、氟化铝、膨润土,这只会提高,或不影响纤维,电弧猝熄化合物和热固树脂组合所达到的参数。
关于图1,依据本发明的熔丝管10例如通过缠绕、模压或挤压形成一狭长的管状体以用作熔丝管或电弧猝熄套管。参见图2,呈狭长管状体的熔丝管16包含一内管12和一外管14。内管12具有中心小孔18,并由电弧猝熄组分制成,以提供所需的电弧猝熄参数。外管14例如通过缠绕或模压围绕内管12形成,为熔丝管16提供额外的强度。内管12的材料是一种含合适电弧猝熄填充剂和纤维内含物的热固树脂,使熔丝管能经过缠绕、模压或挤压过程而制造出来,例如,使材料具有适当的粘滞性和可使用性。紧接着,或最好在内管12凝固前,外管14围绕内管12形成从而避免产生任何电介质或机械界面,内管12和外管14的材料在其界面接合或交联。在一范例中,外管14由包含如玻璃纤维的合适纤维内含物的热固树脂的长丝缠绕而成,以达到所要求的结构强度。
在一说明性实施例中,内管12和外管14的缠绕几乎同时在持续转动的绕丝机上一前一后或依次进行。在其他说明性实施例中,内管12被挤压或模压,外管14缠绕或模压在内管12上,最好使内外管12凝固成单一结构。内管12和外管14的材料经选择使其通过接合和/或交联而凝固成单一结构。这消除了内管12和外管14之间的任何电介质或机械界面或界限,确保内外管保持完整的机械结构并具极强的抗分隔力,如内外管12、14在切断电弧时所承受的“外推”力。
参见图3,如果相对于小孔锥体的数量内管12的缠绕未达到适当的均匀性(例如,由于缠绕线股的重叠造成单个纤维线股不平展),当小孔18的电弧猝熄组分被除去以形成如线20所示小孔锥体时,这实际上延伸出内管12而进入外管14,如22所示,将锥小孔20暴露于外管14的材料。这对于要求小孔具有电弧猝熄参数的熔丝管设计来说当然是极不希望发生的。再参见图4,如果电弧猝熄内管12如说明的那样达到预定的均匀性,则20所示移去材料的小孔锥体不会将锥形小孔20暴露于外管14的材料,而是整体位于内管12的电弧猝熄内层中。举例说,这一特性可被视为23所示的不均匀性或差异性很小而不致影响到25所示的最小壁厚,即,不均匀性不会对锥形小孔20所要求的壁厚产生显著的影响或干扰。当然,在特定应用中的意义取决于25所示的壁厚在电弧猝熄时以及内管12的使用期间预计被侵蚀或融化的厚度。特别说明的是,这可被描述为23所示的不均匀性或差异性明显小于25所示的最小壁厚。并且,外管14的均匀性也很重要,可以尽量减少对外表面的任何机械加工从而得到合适的表面并使强度达到最大。
在一特定的说明性实施例中,熔丝管16的小孔18直径为半英寸,内管12的最终外径为0.72英寸,而熔丝管16的外径为1英寸。在应用于标称额定电压幅度7.2到25千伏时,熔丝管16的长度为9-16英寸。
再详细说一下锥形小孔并参见图5,为便于说明,小孔的锥体被放大,其比例被夸大了很多。举例说,对一标称额定电压为25千伏及12000RMS不对称安培最高断路额度的熔断器来说,就使用五级锥体,将小孔开口在3.5英寸长度上从半英寸增加到0.656英寸,详细情况在上述专利4,313,100中加以描述。对一标称额定电压为25千伏及8000RMS不对称安培最高断路额度的熔断器来说,也使用五级锥体,将小孔开口在5.5英寸长度上从半英寸增加到0.656英寸,详细情况在上述专利4,313,100中作了描述。在图五中特别标出了三个小孔梯级24、26和28,它们使熔丝管16的小孔开口18扩大从而可根据上文所述的尺寸来确定度数为1-3度的夹角″a″和″b″,夹角″a″是位于排出端30的小孔20的开口和梯级24最内部分的夹角,而夹角″b″是位于排出端30的小孔20的开口和梯级24最外部分的夹角。
尽管对本发明的各个实施例进行了说明和描述,但显然对本领域的熟练人员而言还可作出各种修改和变换。因此,所附权利要求书旨在覆盖所有类似的修改和变换,并不脱离本发明的精神和范围。
Claims (7)
1.一种电弧猝熄组分,其特征在于包含按重量占10-30%的蜜胺、占5-50%的纤维以及占20-80%的胶合剂。
2.如权利要求1所述的电弧猝熄组分,其特征在于所述纤维是丙烯酸。
3.如权利要求1所述的电弧猝熄组分,其特征在于所述蜜胺按重量占17-21%。
4.如权利要求3所述的电弧猝熄组分,其特征在于所述胶合剂包含双酚-A环氧树脂和一凝固剂,两者结合按重量占50-60%。
5.如权利要求4所述的电弧猝熄组分,其特征在于所述纤维包含按重量占20-30%的丙烯酸。
6.一种制造电弧猝熄管的方法,所述方法包括将第一纤维缠绕一圈或多圈,然后在电弧猝熄管内形成一预定的锥体,其中,该预定的锥体确定了电弧猝熄管的所需最小壁厚,制成的电弧猝熄管具有所需最小壁厚,以在电弧猝熄管的预期使用中提供预期的电弧猝熄,所述方法包括如此缠绕该电弧猝熄管,使第一纤维平展并在一圈或多圈缠绕的每一个重合点上不重叠,由此使电弧猝熄管的厚度达到预定的合适的均匀性,所述方法还包括在电弧猝熄管内形成预定的锥体,该预定的锥体确定了电弧猝熄管的所需最小壁厚,该预定的合适的均匀性设置成使电弧猝熄管的厚度变化大大小于所需最小壁厚,由此不会对该预定锥体所确定的所需最小壁厚产生影响或干扰。
7.如权利要求6所述的方法,其特征在于进一步包括将第二纤维在第一纤维上缠绕一圈或多圈,第二纤维与第一纤维不同,所述方法还包括缠绕得使第二纤维平展并在一圈或多圈缠绕的每一缠绕上不重叠,由此达到电弧猝熄管厚度的均匀性。
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- 1999-04-01 AU AU23552/99A patent/AU756745B2/en not_active Expired
- 1999-04-01 CN CNB991048032A patent/CN1240094C/zh not_active Expired - Lifetime
- 1999-04-01 BR BRPI9901227-8A patent/BR9901227B1/pt not_active IP Right Cessation
- 1999-04-02 KR KR1019990011530A patent/KR100614559B1/ko not_active IP Right Cessation
-
2003
- 2003-12-08 US US10/729,585 patent/US20040081782A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
---|---|
BR9901227B1 (pt) | 2011-04-19 |
AU2355299A (en) | 1999-10-14 |
US20020041944A1 (en) | 2002-04-11 |
TW486707B (en) | 2002-05-11 |
AU756745B2 (en) | 2003-01-23 |
US20040081782A1 (en) | 2004-04-29 |
CA2267006A1 (en) | 1999-10-03 |
CA2267006C (en) | 2007-10-16 |
US6777043B2 (en) | 2004-08-17 |
BR9901227A (pt) | 2000-01-18 |
KR100614559B1 (ko) | 2006-08-22 |
KR19990082859A (ko) | 1999-11-25 |
CN1231493A (zh) | 1999-10-13 |
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