WO2016145690A1 - 轨道交通车辆用超耐油超耐低温光电综合电缆及其制备方法 - Google Patents

轨道交通车辆用超耐油超耐低温光电综合电缆及其制备方法 Download PDF

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WO2016145690A1
WO2016145690A1 PCT/CN2015/075832 CN2015075832W WO2016145690A1 WO 2016145690 A1 WO2016145690 A1 WO 2016145690A1 CN 2015075832 W CN2015075832 W CN 2015075832W WO 2016145690 A1 WO2016145690 A1 WO 2016145690A1
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resistant
cable
ultra
insulation
oil
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PCT/CN2015/075832
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English (en)
French (fr)
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周佳龙
梁斌
王恒恒
葛永新
沈阳阳
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中天科技装备电缆有限公司
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Publication of WO2016145690A1 publication Critical patent/WO2016145690A1/zh

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    • 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
    • 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
    • H01B7/02—Disposition of insulation
    • 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
    • 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
    • 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
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame

Definitions

  • the invention relates to a novel super oil-resistant, ultra-low temperature resistant, low-smoke halogen-free flame-retardant photoelectric integrated cable for a rail transit vehicle and a key process preparation method thereof, in particular to a high-speed railway passenger car, an EMU or a long-distance transportation vehicle.
  • Heavy-duty trucks provide high-power, high-current and signal-controlled low-temperature-resistant power, control, and communication optoelectronic integrated cables.
  • the most widely used rail vehicle cable is the European standard EN 50264:2008 “Power and control cables for railway locomotives with special fire performance”, EN 50306:2002 “Thin wall insulation for railway locomotives with special fire performance” Cables and DCP rated voltages of 600V and DCP series cables rated at 2000V in the US GE procurement specifications.
  • the European standard cable is characterized by low temperature resistance of -40 °C, resistance to IRM 902# mineral oil 100 ° C ⁇ 72 hours, and resistance to IRM 903 # fuel oil 70 ° C ⁇ 168 hours.
  • the insulation volume resistivity is ⁇ 10 14 ⁇ cm, which can pass the single vertical combustion and bundled flame retardant B and C tests with a toxicity index ⁇ 3.
  • the DAP and DCP series cables in the US GE procurement specifications are characterized by low temperature resistance of -55 ° C, resistance to IRM 902 # mineral oil 150 ° C ⁇ 144 hours, and insulation volume resistivity ⁇ 10 15 ⁇ ⁇ cm.
  • the polyolefin material required in the relevant rail vehicle cable standard is itself oil-resistant.
  • the molecular structure of polyolefin materials can be changed by irradiation crosslinking technology, and the smaller intermolecular force (van der Waals force) in the linear molecular structure of the original polyolefin material is upgraded to a larger intramolecular action in the network structure.
  • the force saturated molecular bond energy
  • which in turn locks the oil molecules immersed between the molecules of the polyolefin material prevents further diffusion and swelling of the molecular structure of the polyolefin material, resulting in a sharp drop in properties such as material strength and elongation at break.
  • the most effective flame retardant system commonly used at this stage is a metal oxide flame retardant system containing Mg(OH) 2 and AL(OH) 3 and other mineral materials. Therefore, in order to enhance the flame retardant performance of the cable, the content of the metal oxide is inevitably increased, and the concentration of the metal ion is increased, which is naturally accompanied by a decrease in the insulation resistance value of the cable.
  • Oil and low temperature resistance, flame retardancy and insulation properties are just two of the more outstanding performances. Therefore, it is also a bottleneck for the successful development of new oil-resistant, ultra-low-temperature, low-smoke and halogen-free flame-retardant cables for rail transit vehicles.
  • the fire performance test of rail transit vehicle cables such as DIN 5510, EN 45545, BS 6853, etc. does not include fire resistance performance, that is, in the case of fire, the cable is continuously energized for a period of time to ensure electrical safety.
  • a new type of ceramized silicone rubber provides a better solution for the development of fire-resistant cables for rail vehicles. If such fireproof, fireproof, flame retardant, low smoke, non-toxic properties are used, ceramic fireproof and refractory silicone rubber extrusion manufacturing is adopted.
  • the residue of the core after burning is a ceramic hard shell, and the hard shell does not melt or fall under the fire environment of 650 ° C to 3000 ° C, thereby providing a strong protective effect. It can guarantee the smooth flow of the signal control loop in the case of fire, stable operation of the equipment, provide a reliable environment for evacuation, and strive for valuable time.
  • the traditional railway information transmission relies entirely on the electric transmission channel.
  • the optical fiber transmission system has many advantages such as large transmission capacity, strong anti-interference ability, stable and reliable information transmission, and long transmission distance.
  • the new type of rail transit vehicle uses a light unit as a communication transmission channel for the ultra-oil resistant, ultra low temperature resistant, low smoke and halogen free flame retardant cable. This eliminates the phenomenon of secondary wiring in rail transit vehicles.
  • the actual size of the outer diameter of the optoelectronic integrated cable is only about 70% of the separately laid size, compared with the separate laying of the cable and the optical cable of the electric unit and the optical unit.
  • the effective use of rail transit vehicles, the economic benefits are obvious and huge.
  • the present invention provides a super oil-resistant ultra-low temperature photoelectric integrated cable for a rail transit vehicle and a key process preparation method thereof.
  • an ultra-oil-resistant ultra-low temperature optoelectronic integrated cable for a rail transit vehicle comprising a power transmission part, a signal control part and an optical communication transmission part, a shielding layer and a sheath layer, wherein the power transmission part is composed of a conductor-clad insulation layer
  • the signal control portion is composed of a ceramized silicone rubber refractory insulated wire core
  • the optical communication transmission portion is composed of a layer twisted dry optical transmission unit, a central tube full dry light unit, a layer twisted light unit or a center tube.
  • One or more components of the filled light unit, the power transmission portion, the signal control portion and the optical communication transmission portion are twisted to form a cable core, and the cable core is covered with a shielding layer, and the shielding layer structure adopts a weaving density of not less than 80% of the shielded monofilament braided shield, the outer diameter of the shielded monofilament is not less than 0.11mm, and the metal composite strip with a thickness of not less than 0.063mm is used for the tow wrap in the shield structure, and the metal surface and the shield layer of the metal composite strip are dragged and dropped.
  • the structure is in contact with each other, or a semi-conductive tape having a single-layer coverage ratio of not less than 20% is used for wrapping, and the shielding layer structure is jacketed with a sheath layer.
  • the conductor adopts a tin-plated or high-strength aluminum-magnesium alloy stranded wire or a copper-clad aluminum-magnesium alloy stranded wire or a tinned round copper stranded wire having a monofilament diameter of 0.18 mm to 0.5 mm and a twisted synthetic section of 0.5 mm 2 to 400 mm 2 .
  • the cross-section of the alloy strands can be increased by 15% in order to obtain an equivalent resistance level. Due to the multi-strand (1+6) strands, the cable is still Has good bending properties. The softness of the cable conductor greatly increases the reliability of the cable under long-term bending and vibration conditions.
  • the signal control core with ceramic fireproof and refractory silicone rubber extrusion manufacturing with fireproof, fireproof, flame retardant, low smoke and non-toxic properties can pass the highest level of BS 6387 in the international fireproof and fire resistant wire and cable.
  • CWZ water spray, vibration and fire test it has the characteristics of white low smoke, no phosphorus nitrogen, no heavy metal, no toxicity, no harm, no melting, no dripping; the safety level of smoke toxicity reaches the highest safety of polymer materials.
  • Level ZA1 will not cause secondary damage to the human body; in line with EU RoHS standards.
  • the insulating layer and the sheath layer are made of super oil resistant, ultra low temperature resistant, flame retardant crosslinked insulating material and sheath material, and the nano additive is mixed to ensure that the cable is resistant to cracking after being cooled at -55 ° C.
  • the light unit is a G-layer twisted dry optical transmission unit, a GX-central tube full dry light unit, a GT-layer twisted filled light unit or a GXT-central tube filled light unit, which satisfies
  • the demand for different information transmission capacity in actual use satisfies the requirements for different degrees of long-distance transmission.
  • the metal composite tape with a thickness of not less than 0.063 mm is required to be towed and dragged in the shielding layer structure.
  • the metal surface of the metal-clad composite tape is in contact with the shielding layer structure, and the semi-conductive tape with a single-layer coverage ratio of not less than 20% can be wrapped to ensure the continuity of the shielding layer and improve the reliability of the shielding layer.
  • Method for preparing oil-resistant and low-temperature resistant photoelectric integrated cable for rail transit vehicle comprising five steps of conductor, insulation, cable-forming and wrapping, shielding and sheathing;
  • insulation and sheath are the key processes.
  • the insulation and sheath materials use a new type of nano-flame retardant in the mixing process.
  • the insulation and sheath materials are used to adsorb the nano-sized particles, so that the insulating and sheathed original rubber are maintained.
  • original toughness and electrical properties it combines the rigidity, dimensional stability and thermal stability of inorganic additives.
  • the mixed materials also have the advantages of fast processing speed, low power consumption and light weight of nano materials; perfect solution The contradiction between flame retardant performance and insulation performance, while accelerating at least 1/2 of production efficiency, two-fold; nano-additives can also be applied to other performance improvements, so that the impact of various properties of the material is minimized;
  • the existing irradiation cross-linking technology is affected by three factors: equipment energy, irradiation dose and line speed; there is often a phenomenon that the degree of cross-linking is not uniform after irradiation on the entire cable circumference, and the large-size cable of 35 mm 2 and above Especially obvious; therefore, the new product uses the silane cross-linking process instead of the original radiation cross-linking process technology; since the silane cross-linking principle is a bridge structure using a grafting agent to form a network structure, so as long as the weight ratio of the grafting agent is controlled
  • the single factor can control the degree of cross-linking of the cable insulation sheath, without over-crosslinking phenomenon, while controlling the oil resistance of the material, it is very close to the lowest temperature resistance level of the material; by controlling the weight of the grafting agent The process of finding the dynamic balance point of each property of the material is visualized.
  • the invention has the advantages that the nano-additive technology utilizes the nano-level particle adsorption by the insulating and sheathing materials, so that the insulating and sheathed original rubber perfectly combines the rigidity of the inorganic auxiliary agent under the premise of maintaining the original toughness and electrical properties.
  • dimensional stability, thermal stability, mixed materials also have the advantages of high processing speed, low power consumption and light weight.
  • Nano-additives can also be applied to other performance improvements to minimize the impact of material properties.
  • the signal is used to control the insulated core of the fireproof, fire-resistant, flame-retardant, low-smoke, non-toxic ceramized fire-retardant and refractory silicone rubber.
  • the residue after burning is a ceramic-like hard shell, and the hard shell is in fire. 650 ° C ⁇ 3000 ° C) does not melt, does not fall, and provides a strong protective effect. It can guarantee the smooth flow of the signal control loop in the case of fire, stable operation of the equipment, provide a reliable environment for evacuation, and strive for valuable time.
  • This cable can meet the rated range of 3.6/6kV and below. It has both an electric unit and a light unit. On the one hand, it integrates signal transmission, power transmission and distribution, and fiber optics to achieve a leap forward. The secondary wiring of the rail transit vehicle is avoided, and the network construction cost is low, which responds to the development idea of the national lightweight high-speed train.
  • the minimum bending radius of the cable can reach 4 times the outer diameter of the cable, which improves the convenience of construction.
  • the cable is resistant to -55 ° C after low temperature winding without cracking; after IRM 902 # mineral oil 150 ° C ⁇ 144 hours, the strength change rate of insulation and sheath material does not exceed ⁇ 30%, and the rate of change of elongation at break does not exceed ⁇ 40% Resistance to IRM 903# fuel oil 70 ° C ⁇ 168 hours after insulation, sheath material strength change rate does not exceed ⁇ 30%, elongation at break change rate does not exceed ⁇ 40%; anti-3000N side pressure characteristics and other special properties to ensure the cable Safety and reliability for long-term stable operation in different complex working environments.
  • the comprehensive improvement of the comprehensive performance of the cable has increased the continuous driving space of the rail transit vehicles, avoiding the occurrence of detours due to the inability to adapt to the replacement of the terrain, energy saving and environmental protection, and meeting the national long-distance high-speed/heavy-duty running trains. Development strategy requirements for regional operations.
  • Figure 1 is a schematic view of the structure of the present invention. Among them: 1, conductor; 2, insulating layer; 3, light unit; 4, metal strip or semi-conductive strip; 5, shielding layer; 6, outer sheath; 7, ceramic silicon rubber refractory insulation control core.
  • an oil-resistant and low-temperature resistant photovoltaic integrated cable for a rail transit vehicle includes a power transmission part, a signal control part, an optical transmission communication part, a shielding layer part and a sheath layer.
  • the power transmission part is composed of the conductor 1 extruded insulation 2, and in order to improve the anti-oxidation and corrosion resistance of the conductor, the tin plating process is used for production.
  • the signal control part is composed of a ceramized silicone rubber refractory insulated core 7, and the optical transmission communication part is composed of the light unit 3. After the conductor 1 is covered with the insulating layer 2, the ceramized silicone rubber refractory insulated core is stranded with the light unit 3. Cable core.
  • the shielding layer part is composed of the shielding layer structure 5.
  • the shielding layer structure 5 adopts a shielded monofilament braided shield with a braiding density of not less than 80%, the outer diameter of the shielded monofilament is not less than 0.11 mm, and the metal strip 4 having a thickness of not less than 0.063 mm is used for the dragging and unloading in the shielding layer structure 5
  • the metal surface is in contact with the shielding layer structure 5.
  • the shielding structure 5 can also be wrapped with a semi-conductive strip 4 having a single layer coverage of not less than 20%, and the shielding layer structure 5 is covered with a sheath layer (6).
  • Conductor 1 is made of tin-plated or high-strength aluminum-magnesium alloy stranded wire or copper-clad aluminum-magnesium alloy stranded wire or tinned round copper stranded wire with a diameter of 0.18mm to 0.5mm of single wire and a cross section of 0.5mm 2 to 400mm 2 .
  • the cross-section of the alloy strands can be increased by 15% in order to obtain an equivalent level of resistance.
  • the cable still has good bending due to the use of multiple strands (1+6) strands. performance.
  • the softness of the cable conductor greatly increases the reliability of the cable under long-term bending and vibration conditions.
  • the insulating layer 2 and the sheath layer 6 are made of super oil-resistant, ultra-low temperature resistant, flame-retardant cross-linked insulating material and sheath material, and the nano-additive is mixed to ensure that the cable is not cracked after being cooled at -55 ° C; Resistance to IRM 902# mineral oil 150 ° C ⁇ 144 hours, insulation, sheath material strength change rate does not exceed ⁇ 30%, elongation at break change rate does not exceed ⁇ 40%; IRM 903 # fuel oil 70 ° C ⁇ 168 hours Insulation, sheath material strength change rate does not exceed ⁇ 30%, elongation at break change rate does not exceed ⁇ 40%; 20 ° C insulation volume resistivity ⁇ 10 15 ⁇ ⁇ cm; can pass a single vertical combustion and bundled flame retardant Class B, Class C test; comprehensive performance of toxicity index ⁇ 3, with superior environmental adaptability, resistance to cyclic stress, and prolonged cable life.
  • the signal control part is composed of a new type of signal-controlled insulated wire core made of ceramic fireproof and refractory silicone rubber extruded with fireproof, fireproof, flame retardant, low smoke and non-toxic properties.
  • the residue after combustion is a ceramic hard shell.
  • the hard shell does not melt or fall under the fire (650 ° C ⁇ 3000 ° C) environment, which plays a strong protective role. It can guarantee the smooth flow of the signal control loop in the case of fire, stable operation of the equipment, provide a reliable environment for evacuation, and strive for valuable time.
  • the optical unit communication portion 3 is a G-layer twisted dry optical transmission unit, a GX-central tube full dry optical unit, a GT-layer twisted filled optical unit, or a GXT-central tube filled optical unit, which satisfies the actual situation.
  • the demand for different information transmission capacity in use satisfies the requirements for different degrees of long-distance transmission.
  • the metal layer 4 having a thickness of not less than 0.063 mm is required to be towed in the shielding layer structure 5, and the metal surface of the metal composite tape is brought into contact with the shielding layer structure 5, and the single layer covering rate may be not less than 20
  • the % semiconductive strip 4 is wrapped.
  • Method for preparing oil-resistant and low-temperature resistant photoelectric integrated cable for rail transit vehicle comprising five steps of conductor, insulation, cable-forming and wrapping, shielding and sheathing;
  • the insulation and sheath are the key processes.
  • the insulation and sheath materials are added with a new type of nano-flame retardant in the mixing process.
  • the nano-level particles are adsorbed by the insulating and sheathing materials, so that the insulating and sheathed original rubber are maintained.
  • original toughness and electrical properties it combines the rigidity, dimensional stability and thermal stability of inorganic additives.
  • the mixed materials also have the advantages of fast processing speed, low power consumption and light weight of nano materials; perfect solution The contradiction between flame retardant performance and insulation performance, while accelerating at least 1/2 of production efficiency, two-fold; nano-additives can also be applied to other performance improvements, so that the impact of various properties of the material is minimized;
  • the existing irradiation cross-linking technology is affected by three factors: equipment energy, irradiation dose and line speed; there is often a phenomenon that the degree of cross-linking is not uniform after irradiation on the entire cable circumference, and the large-size cable of 35 mm 2 and above Especially obvious; therefore, the new product uses the silane cross-linking process instead of the original irradiation cross-linking process technology; since the silane cross-linking principle is a bridge structure using a grafting agent to form a network structure, so as long as the single grafting agent content is controlled
  • the factor can control the degree of cross-linking of the cable insulation sheath, without over-crosslinking phenomenon, while controlling the oil resistance of the material, it is very close to the lowest temperature resistance level of the material; by controlling the content of the grafting agent, Process visualization of the dynamic balance points of various properties of the material.

Abstract

一种轨道交通车辆用超耐油超耐低温光电综合电缆，动力传输部分由导体（1）包覆绝缘层（2）组成，信号控制部分由陶瓷化硅橡胶耐火绝缘线芯（7）组成，光通信传输部分由层绞全干式光传输单元、中心管全干式光单元、层绞填充式光单元或中心管填充式光单元中的一种或几种组成，动力传输部分、信号控制部分与光通信传输部分绞合构成缆芯，缆芯外包覆有屏蔽层结构（5），屏蔽层结构（5）采用编织密度不小于80％的屏蔽单丝编织，屏蔽单丝外径不小于0.11mm，屏蔽层结构内使用厚度不小于0.063mm厚度的金属复合带（4）进行拖包，拖包时金属复合带（4）的金属面与屏蔽层结构相接触，或使用单层搭盖率不小于20％的半导电带（4）进行绕包，屏蔽层结构（5）外套有护套层（6）。

Description

轨道交通车辆用超耐油超耐低温光电综合电缆及其制备方法 技术领域
本发明具体涉及一种新型的轨道交通车辆用超耐油、超耐低温、低烟无卤阻燃光电综合电缆及其关键工序制备方法，特别涉及一种为远距离运输高速铁路客车、动车组或重载货车提供大功率、大电流和信号控制的耐低温动力、控制、通信光电综合电缆。
背景技术
近年，我国城市轨道交通事业高速发展并取得瞩目成就。截至2012年12月31日，仅中国大陆地区就有17个城市70多条城市轨道交通线路投入运营，总运营里程达到2064km。随着城市化进程的不断加快以及解决城市交通问题的迫切需要，各地纷纷加大对城市轨道交通建设的投入，目前不仅省会一级的城市基本都在建设城市轨道交通，而且多个经济比较发达的地级城市也在建设或正在申报建设。根据国内各城市轨道交通建设规划编制和报批进展，预计2020年之前，我国每年新增城市轨道交通运营线路里程基本能超过300km，全国总里程规模将达到目前的2倍。因此目前急需提前做好轨道交通规划和科学研究工作。
我国地域广阔，高原、丘陵、平原以及盆地等地形复杂交错，因此目前国内许多正在进行轨道交通规划、设计的城市普遍遇到车辆运行范围小，无法连续跨区域行驶的问题。轨道交通车辆电缆的性能级别直接决定了拟建铁路交通工程的规模，以及线路、行车组织、系统运能等条件的确定。连续跨区域行驶的轨道交通车辆车体布线所用电缆需同时满足低烟、无卤、阻燃、耐矿物油、耐燃油、耐高温、耐低温、抗外部腐蚀及老化等相互矛盾的性能。因此，研发出一种新型的轨道交通车辆用超耐油、超耐低温、低烟无卤阻燃电缆，势在必行。
随着我国与国外轨道交通车辆制造巨头的深入合作，引入国外交通系统的各种产品制造标准，其中包括欧标、法标、日标、美国GE采购规范等不同体系的轨道交通车辆电缆标准。并且国家在十二五规划中大力发展铁路及其相关产业，在未来几年内给轨道交通车辆电缆带来了非常广阔的市场前景。
现有的使用量最大的轨道交通车辆电缆是满足欧洲标准EN 50264：2008《具有特殊防火性能的铁路机车车辆动力和控制电缆》、EN 50306：2002《具有特殊防火性能的铁路机车车辆薄壁绝缘电缆》和美国GE采购规范中额定电压600V的DAP和额定电压2000V的DCP系列电缆。
其中欧标电缆突出特点为耐-40℃低温，耐IRM 902#矿物油100℃×72小时，耐IRM 903#燃料油70℃×168小时。绝缘体积电阻率≥1014Ω·cm，可通过单根垂直燃烧和成束阻燃B类、C类试验，毒性指数<3。
美国GE采购规范中DAP和DCP系列电缆突出特点为耐-55℃低温，耐IRM 902#矿物油150℃×144小时，绝缘体积电阻率≥1015Ω·cm。
为了能满足我国远距离高速/重载运行列车连续跨区域行驶的发展需求。将欧标和美国GE采购规范中电缆各项性能结合到一起，研发出一种具有电缆耐-55℃低温后卷绕无开裂现象；耐IRM 902#矿物油150℃×144小时后绝缘、护套材料强度变化率不超过±30％，断裂伸长率变化率不超过±40％；耐IRM 903#燃料油70℃×168小时后绝缘、护套材料强度变化率不超过±30％，断裂伸长率变化率不超过±40％。；20℃绝缘体积电阻率≥1015Ω·cm；可通过单根垂直燃烧和成束阻燃B类、C类试验；毒性指数<3性能的具有超强环境适应性，耐循环应力的电缆是很有必要的。
根据相似相溶原理，相关轨道交通车辆电缆标准中要求的聚烯烃材料本身是不耐油的。目前仅可以通过辐照交联技术改变聚烯烃材料的分子结构，将原聚烯烃材料线性分子结构中较小的分子间作用力(范德华力)升级为网状分子结构中较大的分子内作用力(饱和分子键能)，进而锁紧浸入聚烯烃材料分子间的油料分子，防止其进一步扩散溶胀破坏聚烯烃材料的分子结构导致材料强度、断裂伸长率等性能急剧下降的问题产生。但也正因为网状结构中存在较大的分子内作用力(饱和分子键能)因此材料在低温时脆化温度提高，更易开裂。因此电缆耐油性能的提高必定伴随着低温性能的下降。
现阶段常用的效果最好的阻燃体系为添加Mg(OH)2和AL(OH)3及其他矿质材料的金属氧化物阻燃体系。因此为了增强电缆的阻燃性能，必然增加金属氧化物的含量，金属离子的浓度增加，又自然的伴随着电缆绝缘电阻值的下降。
耐油和耐低温性能，阻燃和绝缘性能仅是列举的两个比较突出的此消彼长的性能。因此，也是新型的轨道交通车辆用超耐油、超耐低温、低烟无卤阻燃电缆研发成功的瓶颈。
目前轨道交通车辆电缆通过的防火性能测试如DIN 5510、EN 45545、BS 6853等均不包括耐火性能，即在火灾情况下，电缆在一段时间内仍然持续通电运行，保证电气安全的能力。随着硅橡胶材料的推广应用，一种新型的陶瓷化硅橡胶为轨道交通车辆耐火电缆的研发提供了更好的解决方案。如果采用这种具有防火、耐火、阻燃、低烟、无毒性能的陶瓷化防火、耐火硅橡胶挤出制造。这样缆芯在燃烧后的残留物为陶瓷状硬壳，硬壳在650℃～3000℃的火灾环境下不熔融、不低落，起到坚固的保护作用。可保证在火灾情况下信号控制回路的畅通，设备稳定运行，为人员疏散提供可靠的环境，争取宝贵的时间。
传统的铁路信息传输完全依赖电传输通道，随着铁路信号技术的发展，光纤传输的系统因其具有传输容量大，抗干扰能力强，信息传输稳定可靠，传输距离远等诸多优点，如果能在新型的轨道交通车辆用超耐油、超耐低温、低烟无卤阻燃电缆中加入光单元作为通信传输通道。便杜绝了轨道交通车辆中二次布线的现象，同时，电单元和光单元的绞合成缆与电缆和光缆分开敷设相比，光电综合缆外径实际尺寸仅为分开敷设尺寸的70％左右，增加了轨道交通车辆的有效使用空间，产生的经济效益是显而易见的，是巨大的。
发明内容
发明目的：为了解决现有轨道交通车辆电缆综合性能的不足，本发明提供了一种轨道交通车辆用超耐油耐超低温光电综合电缆及其关键工序制备方法。
技术方案：一种轨道交通车辆用超耐油超耐低温光电综合电缆，包括动力传输部分、信号控制部分和光通信传输部分、屏蔽层和护套层，所述动力传输部分由导体包覆绝缘层组成，所述信号控制部分由陶瓷化硅橡胶耐火绝缘线芯组成，所述光通信传输部分由层绞全干式光传输单元、中心管全干式光单元、层绞填充式光单元或中心管填充式光单元中的一种或几种组成，动力传输部分、信号控制部分与光通信传输部分绞合构成缆芯，缆芯外包覆有屏蔽层，所述屏蔽层结构采用编织密度不小于80％的屏蔽单丝编织屏蔽，屏蔽单丝外径不小于0.11mm，屏蔽层结构内使用厚度不小于0.063mm厚度的金属复合带进行拖包，拖包时金属复合带的金属面与屏蔽层结构相接触，或使用单层搭盖率不小于20％的半导电带进行绕包，屏蔽层结构外套有护套层。
作为优化：所述导体采用单丝直径0.18mm～0.5mm绞合成截面为0.5mm2～400mm2的镀锡或高强度铝镁合金绞线或铜包铝镁合金绞线或镀锡圆铜绞线,当采用高强度的合金绞线时，为得到等效的电阻水平，可将合金绞线的截面增大15％，由于采用的是多股(1+6)绞线的方式，电缆仍然具有良好的弯曲性能。电缆导体的柔软度极大幅度提高了电缆在长期弯曲、振动条件下的可靠性。
作为优化：所述具有防火、耐火、阻燃、低烟、无毒性能的陶瓷化防火、耐火硅橡胶挤出制造的信号控制线芯，可通过国际上防火耐火电线电缆最高级别的BS 6387的CWZ级水喷淋、震动、耐火试验；具有白色低烟、无磷氮、无重金属、无毒、无害、不熔融、不滴落的特点；烟气毒性安全等级达到高分子材料的最高安全级别ZA1级，不会对人体造成二次伤害；符合欧盟RoHS标准。
作为优化：所述绝缘层和护套层采用超耐油、超耐低温、阻燃交联绝缘材料、护套材料，通过混炼纳米添加剂，保证了电缆耐-55℃低温后卷绕无开裂现象；耐IRM 902#矿物油150℃×144小时后绝缘、护套材料强度变化率不超过±30％，断裂伸长率变化率不超过±40％；耐IRM 903#燃料油70℃×168小时后绝缘、护套材料强度变化率不超过±30％，断裂伸长率变化率不超过±40％；20℃绝缘体积电阻率≥1015Ω·cm；可通过单根垂直燃烧和成束阻燃B类、C类试验；毒性指数<3的综合性能，具有超强环境适应性，耐循环应力的性能，延长了电缆使用寿命。按照GB/T 11026.1-2003《电缆绝缘材料耐热性》标准中老化程序和试验结果的判定，通过收集电缆在180℃、165℃、150℃和135℃的寿命终止点后采用阿伦尼乌兹曲线方程进行计算，推导出该绝缘材料在电缆长期运行使用温度90℃时的热寿命大于30年。
作为优化：所述光单元为G-层绞全干式光传输单元、GX-中心管全干式光单元、GT-层绞填充式光单元或GXT-中心管填充式光单元，这样既满足了实际使用中不同信息传输容量的需求，又满足了对不同程度的远距离传输要求。
作为优化：所述屏蔽层结构内需用厚度不小于0.063mm厚度的金属复合带进行拖包，拖 包金属复合带的金属面与屏蔽层结构相接触，也可以使用单层搭盖率不小于20％的半导电带进行绕包，保证屏蔽层的连续性，提高屏蔽层的可靠性。
一种轨道交通车辆用耐油耐低温光电综合电缆的制备方法，包括导体，绝缘，成缆及绕包，屏蔽，护套共5个工序；
其中，绝缘和护套为关键工序，绝缘、护套材料在混炼过程中采用新型的纳米阻燃剂，通过绝缘、护套材料对纳米级别的粒子吸附，使绝缘、护套原胶在保持原有韧性及电性能的前提下，完美结合了无机助剂的刚性、尺寸稳定性、热稳定性，混合材料同时兼备了纳米材料加工速度快、功耗低、重量轻的优点；完美的解决了阻燃性能与绝缘性能之间的矛盾，同时加快至少1/2的生产效率，一举两得；纳米添加剂同样可以应用在其他性能的改进方面，使材料各性能间的影响程度降到最低；
现有辐照交联技术受设备能量、辐照剂量和进线速度三个因素的影响；经常存在整根电缆圆周上辐照后交联度不均匀的现象，35mm2及以上的大规格电缆尤为明显；因此该新产品采用硅烷交联工艺代替原有辐照交联工艺技术；由于硅烷交联原理为利用接枝剂的桥架作用构成网状分子结构，因此只要控制接枝剂重量配比的单一因素即可控制电缆绝缘护套的交联度，无过交联现象的发生，在控制材料耐油性能的同时，极大的接近了材料最低的耐温等级；通过控制接枝剂的重量，将寻找材料各性能动态平衡点的过程可视化。
有益效果：本发明利用纳米添加剂技术，通过绝缘、护套材料对纳米级别的粒子吸附，使绝缘、护套原胶在保持原有韧性及电性能的前提下，完美结合了无机助剂的刚性、尺寸稳定性、热稳定性，混合材料同时兼备了纳米材料加工速度快、功耗低、重量轻的优点。完美的解决了阻燃性能与绝缘性能之间的矛盾，同时加快至少1/2的生产效率，一举两得。纳米添加剂同样可以应用在其他性能的改进方面，使材料各性能间的影响程度降到最低。
采用新型具有防火、耐火、阻燃、低烟、无毒性能的陶瓷化防火、耐火硅橡胶挤出制造的信号控制绝缘线芯在燃烧后的残留物为陶瓷状硬壳，硬壳在火灾(650℃～3000℃)环境下不熔融、不低落，起到坚固的保护作用。可保证在火灾情况下信号控制回路的畅通，设备稳定运行，为人员疏散提供可靠的环境，争取宝贵的时间。
采用新型的纳米阻燃剂，同时提高阻燃、绝缘和耐油、耐低温等性能。减小电缆材料间各性能的相互影响作用，响应了国家科技发展政策。
结合我国地域广阔，温带、亚热带季风气候明显的特性，在列车长距离、大温差、高震动频率运行的过程中，通过采用这种新型低烟无卤阻燃交联聚烯烃材料来改善电缆耐磨性、耐化学药品性、耐应力开裂等一系列物理、化学性能，将为轨道交通车辆的运行提供安全保障。
该电缆可满足额定电压3.6/6kV及以下的使用范围。同时具有电单元和光单元。一方面集信号传输、电力输配电和光纤于一身，实现了一缆多能的飞跃式前进。避免了轨道交通车辆的二次布线，网络建设费用低，响应了国家轻量化高速列车的发展思路。
通过改善电缆导体结构，增加电缆柔软度，电缆最小弯曲半径可达4倍电缆外径，提高了施工的便捷性。
电缆耐-55℃低温后卷绕无开裂现象；耐IRM 902#矿物油150℃×144小时后绝缘、护套材料强度变化率不超过±30％，断裂伸长率变化率不超过±40％；耐IRM 903#燃料油70℃×168小时后绝缘、护套材料强度变化率不超过±30％，断裂伸长率变化率不超过±40％；抗3000N侧压特性等特殊性能保证了电缆在不同复杂的工作环境下长期稳定运行的安全性和可靠性。
电缆综合性能的大幅提升使轨道交通车辆连续行驶空间范围增大，避免了轨道交通车辆由于无法适应地形的更换而走弯路情况的发生，节能环保，满足国家远距离高速/重载运行列车连续跨区域运行的发展战略要求。
附图说明
图1为本发明的结构示意图。其中:1、导体；2、绝缘层；3、光单元；4、金属带或半导电带；5、屏蔽层；6、外护层；7、陶瓷化硅橡胶耐火绝缘控制线芯。
具体实施方式
下面结合具体实施例对本发明作进一步说明。
实施例
如图1所示，一种轨道交通车辆用耐油耐低温光电综合电缆，包括动力输部分、信号控制部分、光传输通信部分、屏蔽层部分和护套层。动力输部分由导体1挤包绝缘2组成，为了提高导体抗氧化，耐腐蚀性能，采用镀锡工艺进行生产。信号控制部分由陶瓷化硅橡胶耐火绝缘线芯7组成，光传输通信部分由光单元3组成，导体1包覆绝缘层2后和陶瓷化硅橡胶耐火绝缘线芯与光单元3进行绞合构成缆芯。屏蔽层部分由屏蔽层结构5组成，在具有很强电磁场的干扰区段内，为防止线芯中的感应电流影响电能的传输，导致供电不稳或供电系统瘫痪，光电综合缆的屏蔽层结构5是必需的。屏蔽层结构5采用编织密度不小于80％的屏蔽单丝编织屏蔽，屏蔽单丝外径不小于0.11mm，屏蔽层结构5内使用厚度不小于0.063mm厚度的金属带4进行拖包，拖包的金属面与屏蔽层结构5相接触，屏蔽结构5内也可使用单层搭盖率不小于20％的半导电带4进行绕包，屏蔽层结构5外套有护套层(6)。
导体1采用单丝直径0.18mm～0.5mm绞合成截面为0.5mm2～400mm2的镀锡或高强度铝镁合金绞线或铜包铝镁合金绞线或镀锡圆铜绞线,当采用高强度的合金绞线时，为得到等效的电阻水平，可将合金绞线的截面增大15％，由于采用的是多股(1+6)绞线的方式，电缆仍然具有良好的弯曲性能。电缆导体的柔软度极大幅度提高了电缆在长期弯曲、振动条件下的可靠性。
所述绝缘层2和护套层6采用超耐油、超耐低温、阻燃交联绝缘材料、护套材料，通过混炼纳米添加剂，保证了电缆耐-55℃低温后卷绕无开裂现象；耐IRM 902#矿物油150℃×144小时后绝缘、护套材料强度变化率不超过±30％，断裂伸长率变化率不超过±40％；耐IRM 903#燃料油70℃×168小时后绝缘、护套材料强度变化率不超过±30％，断裂伸长率变化率不超过±40％；20℃绝缘体积电阻率≥1015Ω·cm；可通过单根垂直燃烧和成束阻燃B类、C类试验； 毒性指数<3的综合性能，具有超强环境适应性，耐循环应力的性能，延长了电缆使用寿命。按照GB/T 11026.1-2003《电缆绝缘材料耐热性》标准中老化程序和试验结果的判定，通过收集电缆在180℃、165℃、150℃和135℃的寿命终止点后采用阿伦尼乌兹曲线方程进行计算，推导出该绝缘材料在电缆长期运行使用温度90℃时的热寿命大于30年。
信号控制部分采用新型具有防火、耐火、阻燃、低烟、无毒性能的陶瓷化防火、耐火硅橡胶挤出制造的信号控制绝缘线芯组成，在燃烧后的残留物为陶瓷状硬壳，硬壳在火灾(650℃～3000℃)环境下不熔融、不低落，起到坚固的保护作用。可保证在火灾情况下信号控制回路的畅通，设备稳定运行，为人员疏散提供可靠的环境，争取宝贵的时间。
光单元通信部分3为G-层绞全干式光传输单元、GX-中心管全干式光单元、GT-层绞填充式光单元或GXT-中心管填充式光单元，这样既满足了实际使用中不同信息传输容量的需求，又满足了对不同程度的远距离传输要求。
所述屏蔽层结构5内需用厚度不小于0.063mm厚度的金属复合带4进行拖包，拖包金属复合带的金属面与屏蔽层结构5相接触，也可以使用单层搭盖率不小于20％的半导电带4进行绕包。
一种轨道交通车辆用耐油耐低温光电综合电缆的制备方法，包括导体，绝缘，成缆及绕包，屏蔽，护套共5个工序；
其中，绝缘和护套为关键工序，绝缘、护套材料在混炼过程中加入新型的纳米阻燃剂，通过绝缘、护套材料对纳米级别的粒子吸附，使绝缘、护套原胶在保持原有韧性及电性能的前提下，完美结合了无机助剂的刚性、尺寸稳定性、热稳定性，混合材料同时兼备了纳米材料加工速度快、功耗低、重量轻的优点；完美的解决了阻燃性能与绝缘性能之间的矛盾，同时加快至少1/2的生产效率，一举两得；纳米添加剂同样可以应用在其他性能的改进方面，使材料各性能间的影响程度降到最低；
现有辐照交联技术受设备能量、辐照剂量和进线速度三个因素的影响；经常存在整根电缆圆周上辐照后交联度不均匀的现象，35mm2及以上的大规格电缆尤为明显；因此该新产品采用硅烷交联工艺代替原有辐照交联工艺技术；由于硅烷交联原理为利用接枝剂的桥架作用构成网状分子结构，因此只要控制接枝剂含量的单一因素即可控制电缆绝缘护套的交联度，无过交联现象的发生，在控制材料耐油性能的同时，极大的接近了材料最低的耐温等级；通过控制接枝剂的含量，将寻找材料各性能动态平衡点的过程可视化。
结合我国地域广阔，温带、亚热带季风气候明显的特性，在列车长距离、大温差、高震动频率运行的过程中，通过采用这种新型低烟无卤阻燃交联聚烯烃材料来改善电缆耐磨性、耐化学药品性、耐应力开裂等一系列物理、化学性能，将为轨道交通车辆的运行提供安全保障。
对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (7)

  1. 一种轨道交通车辆用超耐油超耐低温光电综合电缆，其特征在于：包括动力传输部分、信号控制部分、光通信传输部分、屏蔽层和护套层，所述动力传输部分由导体(1)包覆绝缘层(2)组成，所述信号控制部分由陶瓷化硅橡胶耐火绝缘线芯(7)组成，所述光通信传输部分由光单元(3)组成，导体(1)包覆绝缘层(2)后和陶瓷化硅橡胶耐火绝缘线芯(7)与光单元(3)进行绞合构成缆芯，所述屏蔽层结构(5)采用编织密度不小于80％的屏蔽单丝编织屏蔽，屏蔽单丝外径不小于0.11mm，屏蔽结构(5)内使用厚度不小于0.063mm厚度的金属复合带(4)进行拖包，拖包金属复合带的金属面与屏蔽结构(5)相接触，或使用单层搭盖率不小于20％的半导电带(4)进行绕包，屏蔽结构(5)外包覆有护套层(6)。
  2. 根据权利要求1所述的轨道交通车辆用超耐油超耐低温光电综合电缆，其特征在于：所述导体(1)采用单丝直径0.18mm～0.5mm绞合成截面为0.5mm2～400mm2的镀锡或高强度铝镁合金绞线或铜包铝镁合金绞线或镀锡圆铜绞线。
  3. 根据权利要求1所述的轨道交通车辆用超耐油超耐低温光电综合电缆，其特征在于：所述陶瓷化硅橡胶耐火绝缘线芯(7)由具有防火、耐火、阻燃、低烟、无毒性能的陶瓷化防火、耐火硅橡胶挤出制成，缆芯在燃烧后的残留物为陶瓷状硬壳，硬壳在650℃～3000℃的火灾环境下不熔融、不低落，起到坚固的保护作用，保证在火灾情况下信号控制回路的畅通，设备稳定运行。
  4. 根据权利要求1所述的轨道交通车辆用超耐油超耐低温光电综合电缆，其特征在于：所述绝缘层(2)和护套层(6)采用超耐油、超耐低温、阻燃交联绝缘材料、护套材料，通过混炼纳米添加剂，保证电缆耐-55℃低温后卷绕无开裂现象；耐IRM 902#矿物油150℃×144小时后绝缘、护套材料强度变化率不超过±30％，断裂伸长率变化率不超过±40％；耐IRM 903#燃料油70℃×168小时后绝缘、护套材料强度变化率不超过±30％，断裂伸长率变化率不超过±40％。；20℃绝缘体积电阻率≥1015Ω·cm。
  5. 根据权利要求1所述的轨道交通车辆用超耐油超耐低温光电综合电缆，其特征在于：所述光单元(3)为G-层绞全干式光传输单元、GX-中心管全干式光单元、GT-层绞填充式光单元或GXT-中心管填充式光单元。
  6. 根据权利要求1所述的轨道交通车辆用超耐油超耐低温光电综合电缆，其特征在于：所述屏蔽结构(5)内需用厚度不小于0.063mm厚度的金属复合带(4)进行拖包，拖包金属复合带的金属面与屏蔽结构(5)相接触，也可以使用单层搭盖率不小于20％的半导电带(4)进行绕包。
  7. 一种轨道交通车辆用超耐油超耐低温光电综合电缆的制备方法，其特征在于：包括导体，绝缘，成缆及绕包，屏蔽，护套共5个工序；
    其中，绝缘和护套为关键工序，绝缘、护套材料在混炼过程中加入新型的纳米阻燃剂，通过绝缘、护套材料对纳米级别的粒子吸附，使绝缘、护套原胶在保持原有韧性及电性能的 前提下，完美结合了无机助剂的刚性、尺寸稳定性、热稳定性，混合材料同时兼备了纳米材料加工速度快、功耗低、重量轻的优点；采用硅烷交联工艺，利用接枝剂的桥架作用构成网状分子结构，只要控制接枝剂重量配比的单一因素即可控制电缆绝缘护套的交联度，无过交联现象的发生，在控制材料耐油性能的同时，极大的接近了材料最低的耐温等级；通过控制接枝剂的含量，使寻找材料各性能动态平衡点的过程可视化。
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