CN106009237A - 10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料及其制备方法 - Google Patents
10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料及其制备方法 Download PDFInfo
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Abstract
本发明涉及绝缘材料领域，尤其涉及10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料及其制备方法。该绝缘材料按重量百分比计由以下的组分制备得到：LLDPE‑7042、LLDPE‑8320、LDPE、EVA、PP、硅烷偶联剂、交联剂DCP、抗氧剂300、抗氧剂1010、抗氧剂DLTP、抗氧剂1024、有机锡、氟橡胶母料。本材料主要用于电缆的绝缘层，以取代目前的PVC材料为主，绝缘性能优于PVC，而PVC在电线老化等起火的时候会放出有毒有害气体，而硅烷绝缘料无毒无害。
Description
技术领域
本发明涉及绝缘材料领域，尤其涉及10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料及其制备方法。
背景技术
电缆行业使用聚烯烃的品种主要有PE、PP、EVA及EEA等，其中相对量大、应用历史长的主要是PE，它有HDPE、MDPE、LDPE、LLDPE及经过交联的XLPE，它们的应用已毋需多说。行业中现今聚烯烃的应用和发展趋势主要集中在以下几方面：
(1)无卤低烟材料的系列化、完善化
无卤低烟阻燃电缆料是近年来发展较快的品种，符合IEC92-359标准要求的热塑型料已得到越来越广泛的应用。随着石油平台、核电站、舰船用电缆及其他环境恶劣的使用场合的要求，交联型无卤低烟电缆料的应用范围将会越来越大。
(2)耐电痕料
耐电痕电缆料是随着ADSS(全介质自承式架空光缆)的推广应用，而逐渐引起大家的注意的。其实，在10kV及以上架空电缆为防止在潮湿状况下产生电晕已有耐电痕要求，由于其绝缘材料(XLPE、HDPE)本身具有一定的耐电痕性，基本能保证架空电缆耐电痕的要求，故而问题并不突出。而ADSS主要是沿着110KV、220KV的高压线路附设，其护套的耐电蚀性将直接影响光缆寿命，故对护套材料的耐电痕性有较为苛刻的要求，即在施加实际使用拉力的90％张力情况下，进行1000小时的耐电痕试验，它需要有为此专门设计的配方体系，其中的关键即为耐电痕剂的使用、优越的物理机械性能、良好工艺加工性的平衡。目前，英、德、美等国对ADSS的寿命研究还在继续，其重点还是如何提高置于空间电场中电缆护套材料的抗电蚀性。
(3)硅烷交联料
硅烷交联聚乙烯绝缘料在3KV及以下的力缆中已普遍使用。随着硅烷交联技术的普及，其它如硅烷交联可剥离屏蔽料、无卤低烟阻燃料、乙丙电缆料已相继有产品问世。国内在硅烷交联可剥离屏蔽料上已有厂家做了工作，而硅烷交联无卤阻燃料、乙丙电缆料尚少为大家了解，当然更谈不上应用了。
(4)辐照交联聚烯烃料
辐照交联材料及技术在电力电缆、架空电缆及装备线上已得到成熟的应用。众所周知，行业中105℃及以下温度等级，无论用XLPE、XLPVC或PVC都可满足要求，150℃以上，硅橡胶、氟塑料、聚酰亚胺等品种的应用也已成熟，但在中间温度等级(如125℃、150℃)的应用开发上，与国外差距比较大。
发明内容
为了解决上述的技术问题，本发明的目的是提供10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料。本材料主要用于电缆的绝缘层，以取代目前的PVC材料为主，绝缘性能优于PVC，而PVC在电线老化等起火的时候会放出有毒有害气体，而硅烷绝缘料无毒无害。
为了实现上述的目的，本发明采用了以下的技术方案：
10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料，该绝缘材料按重量百分比计由以下的组分制备得到：
所述的催化剂母料由以下的组分制备得到：
作为优选，该绝缘材料按重量百分比计由以下的组分制备得到：
所述的催化剂母料由以下的组分制备得到：
二步法制备10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料的方法，该方法包括以下的步骤：
1)催化剂母料制备：将以上催化剂母料的材料在搅拌机里搅拌，先低速搅拌1分钟再高速搅拌3分钟，然后放出倒入挤出机料斗，挤出机温度：140～180℃，经双螺杆挤出后经过冷却水槽进行冷却，再经过风机吹干后进行切粒，颗粒在干燥塔，设置80℃烘干2小时以上然后用真空铝塑袋进行包装、暂时存放；
2)成品制备：
2.1)将硅烷偶联剂、交联剂DCP、抗氧剂300按照比例进行混合，混合后成为硅烷助剂，充分混合后硅烷助剂待用；
2.2)LLDPE-7042、LLDPE-8320、LDPE、EVA、催化母料按比例吸入到搅拌机进行混合，混合均匀后吸入干燥塔，设定60℃，烘干时间大于半个小时，之后将材料吸入原料料仓；
2.3)以上物料经计量称自动加料加入到双螺杆挤出机，将已经配好的硅烷助剂也经过计量称在第二区加入到双螺杆，以上材料在双螺杆进行接枝；
2.4)经双螺杆接枝后的材料经单螺杆挤出、偏心水雾切粒，经输送水泵输送到脱水机，经脱水后由输送风机输送至沸腾床，通过控制料位的高度对材料进行充分干燥，后由真空吸料机吸入成品料仓；
2.5)计量、包装即为成品。
一步法制备10kV及以下电线电缆用硅烷交联聚乙烯绝缘料的方法，该方法包括以下的步骤：
1)催化剂母料制备：将以上催化剂母料的材料在搅拌机里搅拌，先低速搅拌1分钟再高速搅拌3分钟，然后放出倒入挤出机料斗，挤出机温度：140～180℃，经双螺杆挤出后经过冷却水槽进行冷却，再经过风机吹干后进行切粒，颗粒在干燥塔，设置80℃烘干2小时以上然后用真空铝塑袋进行包装、暂时存放；
2)成品制备：
2.1)将硅烷偶联剂、交联剂DCP、抗氧剂300按照比例进行混合，混合后成为硅烷助剂，充分混合后硅烷助剂待用；
2.2)将主设备双锥转鼓进行加热到90℃；
2.3)LLDPE-7042、LLDPE-8320、LDPE、EVA、催化母料按比例吸入到双锥转鼓内，然后将盖子密闭，开启双锥转鼓进行干燥、混合；
2.4)以上物料干燥、混合2.5小时后，通过液体喷淋装置将备用的硅烷助剂加入到物料内；
2.5)硅烷助剂经过2.5小时的吸收后放出；
2.6)计量、包装即为成品。
本发明由于采用了上述的技术方案，本发明的材料主要用于电缆的绝缘层，以取代目前的PVC材料为主，绝缘性能优于PVC，而PVC在电线老化等起火的时候会放出有毒有害气体，而硅烷绝缘料无毒无害。
使用本发明的产品生产，螺杆转速及电流稳定，生产240mm2，放线速度每分钟4.5米；在挤出时，出胶均匀，无颗粒，连续开机12天无老胶出现；电缆热延伸检测在70％～80％，永久变形在0～5％范围内；局部放电检测在2PC以内，工频耐压试验30分钟无击穿；半成品、成品检测均符合GB/T 12706-2002要求。
本发明的产品与聚氯乙烯比较，抗热变性比PvC好，抗过载能力强。短路运行温度最高可达250℃。而PVC耐热性差，其80℃持续4h其变性可达50％。当电缆过载运行时易造成绝缘老化及软化变性而引起击穿，PVC老化引起电缆火灾事故占电火灾事故总数的50％；交联聚乙烯密度比聚氯乙烯小40％左右，可以明显减轻线缆的质量。与热塑性聚乙烯比较，提高了耐热变形性，改善了高温下的力学性能，改进了耐环境应力龟裂与耐热老化性能，增强了耐化学稳定性和耐溶剂性，减少了冷流性，绝缘电阻高，介质损耗角正切小，基本上不随温度的改变而改变，基本保持了原来的电气性能。
具体实施方式
实施例1
10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料，该绝缘材料按重量百分比计由以下的组分制备得到：
二步法制备10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料的方法，主要由两部分组成，一是催化剂母料的制备，二是成品制备。
1、催化剂母料制备：催化剂母料占总材料成分的5％，具体配方如下：
将以上材料(共50公斤)在搅拌机里搅拌，先低速搅拌1分钟再高速搅拌3分钟，然后放出倒入挤出机料斗(挤出机温度：140～180℃)，经双螺杆挤出后经过冷却水槽进行冷却，再经过风机吹干后进行切粒，颗粒在干燥塔(设置80℃)烘干2小时以上然后用真空铝塑袋进行包装、暂时存放。
2、成品制备：
2.1)将硅烷偶联剂、交联剂、抗氧剂300按照1.6％：0.13％：0.04％的比例进行混合(混合后成为硅烷助剂)，充分混合后硅烷助剂待用；
2.2)将LLDPE-7042、LLDPE-8320、LDPE、EVA、催化母料按照40％：20％：25％：8.23％：5％的比例吸入到搅拌机进行混合，混合均匀后吸入干燥塔，设定60℃，烘干时间大于半个小时，之后将材料吸入原料料仓；
2.3)以上物料经计量称自动加料加入到双螺杆挤出机，将已经配好的硅烷助剂也经过计量称在第二区加入到双螺杆，以上材料在双螺杆进行接枝；
2.4)经双螺杆接枝后的材料经单螺杆挤出、偏心水雾切粒，经输送水泵输送到脱水机，经脱水后由输送风机输送至沸腾床，通过控制料位的高度对材料进行充分干燥，后由真空吸料机吸入成品料仓；
2.4)计量、包装即为成品。
2.5)对以上制备的产品进行检测，检测结果为合格。
实施例2
10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料，该绝缘材料按重量百分比计由以下的组分制备得到：
上述的绝缘材料采用实施例1的二步法制备绝缘材料。
实施例3
10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料，该绝缘材料按重量百分比计由以下的组分制备得到：
一步法制备10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料的方法。主要由两部分组成，一是催化剂母料的制备，二是成品制备。
一、催化剂母料制备：催化剂母料占总材料成分的5％，具体配方如下：
将以上材料(共50公斤)在搅拌机里搅拌，先低速搅拌1分钟再高速搅拌3分钟，然后放出倒入挤出机料斗(挤出机温度：140～180℃)，经双螺杆挤出后经过冷却水槽进行冷却，再经过风机吹干后进行切粒，颗粒在干燥塔(设置80℃)烘干2小时以上然后用真空铝塑袋进行包装、暂时存放。
二、成品制备：
1、将硅烷偶联剂、交联剂、抗氧剂300按照1.6％：0.13％：0.04％的比例进行混合(混合后成为硅烷助剂)，充分混合后硅烷助剂待用；
2、将主设备双锥转鼓进行加热到90℃；
3、将LLDPE-7042、LLDPE-8320、LDPE、EVA、催化母料按照40％：20％：25％：8.23％：5％的比例吸入到双锥转鼓内，然后将盖子密闭，开启双锥转鼓进行干燥、混合；
4、以上物料干燥、混合2.5小时后，通过液体喷淋装置将备用的硅烷助剂加入到物料内；
5、硅烷助剂经过2.5小时的吸收后放出；
6、计量、包装即为成品。
7、对以上制备的产品进行检测，检测结果为合格。
实施例4
10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料，该绝缘材料按重量百分比计由以下的组分制备得到：
上述的绝缘材料采用实施例3的一步法制备绝缘材料。
Claims (2)
1.10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料，其特征在于该绝缘材料按重量百分比计由以下的组分制备得到：
以及催化剂母料；
所述的催化剂母料由以下的组分制备得到：
2.根据权利要求1所述的10kV及以下电线电缆用硅烷交联聚乙烯绝缘材料，其特征在于该绝缘材料按重量百分比计由以下的组分制备得到：
以及催化剂母料；
所述的催化剂母料由以下的组分制备得到：
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