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WO2020103660A1 - 一种纵向径向阻水中压电力电缆的制造方法及电缆 - Google Patents

一种纵向径向阻水中压电力电缆的制造方法及电缆

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Publication number
WO2020103660A1
WO2020103660A1 PCT/CN2019/114389 CN2019114389W WO2020103660A1 WO 2020103660 A1 WO2020103660 A1 WO 2020103660A1 CN 2019114389 W CN2019114389 W CN 2019114389W WO 2020103660 A1 WO2020103660 A1 WO 2020103660A1
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WO
WIPO (PCT)
Prior art keywords
layer
water
tape
zone
wrapping
Prior art date
Application number
PCT/CN2019/114389
Other languages
English (en)
French (fr)
Inventor
凌国桢
刘雄军
陈林
Original Assignee
江苏上上电缆集团有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 江苏上上电缆集团有限公司 filed Critical 江苏上上电缆集团有限公司
Publication of WO2020103660A1 publication Critical patent/WO2020103660A1/zh

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Classifications

    • 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
    • H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/02—Stranding-up
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/24—Sheathing; Armouring; Screening; Applying other protective layers by extrusion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/32—Filling or coating with impervious material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/32—Filling or coating with impervious material
    • H01B13/321—Filling or coating with impervious material the material being a powder
    • 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
    • H01B7/2813—Protection against damage caused by electrical, chemical or water tree deterioration
    • 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
    • H01B7/282—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
    • H01B7/2825—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable using a water impermeable sheath
    • 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
    • H01B7/282—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
    • H01B7/285—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable by completely or partially filling interstices in the cable
    • 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
    • H01B7/282—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
    • H01B7/285—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable by completely or partially filling interstices in the cable
    • H01B7/288—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable by completely or partially filling interstices in the cable using hygroscopic material or material swelling in the presence of liquid
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00—Power cables
    • H01B9/02—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients
    • H01B9/021—Features relating to screening tape per se

Definitions

  • the invention relates to the technical field of cables, and in particular relates to a method for manufacturing a multi-core longitudinal radial water-blocking power cable and a cable.
  • the cables are distributed in all corners, and the installation and use environment are very different. After the cable arrives at the construction site, it is generally placed in the open air. Once the head cap is removed and the seal is not good, it is inevitable that water vapor will seep into the cable; when laying the cable, it is necessary to often cross roads, bridges and culverts, etc. due to weather or geography and other reasons, A lot of water often accumulates around the cable. During the production process of the cable head, long-term exposure or negligence by the construction personnel will inevitably cause the cable head to be immersed in the water; sometimes the sheath will be scratched when pulling and passing the tube This phenomenon is especially prominent when mechanical traction is used.
  • the purpose of the invention is to provide a longitudinal radial water-blocking power cable that effectively reduces the breakdown failure rate of the cable.
  • the present invention creates and proposes a manufacturing method and cable for a longitudinal radial water-resistant power cable, specifically:
  • a method for manufacturing a longitudinal radial water-blocking power cable the steps include: 1) manufacturing a wire core; 2) manufacturing a cable core; 3) manufacturing a protective layer.
  • the step 1) includes:
  • the step 2) includes:
  • step 1) the cable is wrapped with a second layer of water-resistant expansion tape and a metal shield layer in sequence;
  • the step 3) includes:
  • step 2) the first cable wrap layer, the radial waterproof layer and the first sheath layer are wrapped around the prepared cable in sequence;
  • the step 1.2) includes:
  • the first layer of water-blocking expansion strip is composed of one or more layers of semi-conducting resistance water-wrap, and the average overlap rate of the wrap is not less than 15%;
  • the first wrapping tape layer is composed of wrapping tape wrapping, the wrapping tape is a double-sided insulating water blocking tape, the average overlapping rate of the wrapping is not less than 15%, the minimum overlap is not less than 5mm; double-sided insulating water blocking
  • the nominal thickness of the belt is at least 0.35mm;
  • the radial waterproof layer is composed of an aluminum-plastic composite tape longitudinally wrapped around the first wrapping tape layer along the axis direction of the cable core, and the requirements include:
  • the thickness of the aluminum-plastic composite tape is not less than 0.25mm, the plastic parts of the left and right sides of the aluminum-plastic composite tape are hot-melt bonded, and the overlapping part is not less than 5mm;
  • Thermocouples are used to heat the aluminum-plastic composite tape in the horn die, wire stabilizing die, and sizing die to make the plastic film soften and sticky, so that the two longitudinal edges overlap and are subsequently extruded with polyethylene
  • the sheath is tightly bonded, and the temperature of the three molds is set to 120 °C, 140 °C and 160 °C in sequence;
  • thermoelectric blower in front of the three molds respectively, aligning the gap between the two longitudinal edges, heating and softening the coating to make it sticky, and the heating temperature is set to 140 °C, 160 °C and 160 in sequence °C;
  • the first sheath layer is extruded polyethylene sheath material outside the radial waterproof layer.
  • the technological requirements include:
  • the temperature distribution of each zone of the extruder is: the temperature range of the first zone is 170 °C ⁇ 180 °C; the temperature range of the second zone, the third zone and the fourth zone are all 175 °C ⁇ 185 °C; the temperature range of the five zones and six zones are 180 °C ⁇ 190 °C;
  • the first zone is the feeding section
  • the second zone, the third zone and the fourth zone are the plasticizing section
  • the fifth zone and the sixth zone are the homogenizing section
  • the temperature of the head unit of the extruder is: the temperature range of the neck is 185 to 195 ° C, the temperature range of the head is 185 to 195 ° C, and the temperature range of the die is 185 to 195 ° C;
  • the jacket should be cooled in stages.
  • the water temperature of the cooling water tank in the first stage should be 50 ⁇ 70 °C, and the normal temperature water should be used thereafter.
  • the metallic monofilament of the conductor is made of copper monofilament or aluminum monofilament; the water-blocking material is water-blocking expansion yarn, water-blocking expansion band or water-blocking expansion powder.
  • the semi-conductive conductor shielding layer, water-resistant tree cross-linked polyethylene insulation layer and semi-conductive insulation shielding layer are composed of three layers of co-extruded corresponding cable materials, and the process requirements are:
  • the temperature of the semi-conductive conductor shielding layer (eight-stage heating) extruder is sequentially set as:
  • the temperature setting deviation is ⁇ 5 ° C;
  • the temperature of the water-resistant tree-shaped cross-linked polyethylene insulation layer (eight-stage heating) extruder is set to 80 °C in the first zone, 116 °C in the second zone, 118 °C in the third zone, 120 °C in the fourth zone, 120 °C in the fifth zone, neck 120 °C, machine head 120 °C and 1 die 20 °C, temperature setting deviation ⁇ 5 °C;
  • the temperature of the semi-conductive insulating shielding layer (eight-segment heating) extruder is set to 60 °C in the first zone, 95 °C in the second zone, 105 °C in the third zone, 112 °C in the fourth zone, 112 °C in the fifth zone, 112 °C in the neck, and the machine head 112 °C and die opening 112 °C, the temperature setting deviation is ⁇ 5 °C;
  • Cooling uses cold water cooling
  • the metal shielding layer is a copper wire shielding layer; the outer surface of the copper wire shielding layer is bound by a copper wire or a copper tape wrapped in reverse; the average gap of adjacent copper wires of the copper wire shielding layer is not more than 4mm;
  • the metal shielding layer is a copper tape shielding layer, and the copper tape shielding layer is composed of one or more layers of overlapped soft copper tape; the average covering rate of the wrapping is not less than 15%, and the minimum covering rate is not less than 5 %, The nominal thickness of the copper strip is not less than 0.12mm;
  • the nominal thickness of the first sheath layer is not less than 1.4mm.
  • Step 2.2 Twist the multiple cables prepared in step 2.1). After the twisting, the metal shielding layer of each cable is the same conduction;
  • the step 3) further includes:
  • Step 3.2) the cable is wrapped with a metal armor layer, a second wrapping tape layer and a second sheath layer in sequence;
  • the plurality of wires around the first cladding step 2.1) are filled and filled between the cables;
  • the jacket should be cooled in stages.
  • the water temperature of the first cooling water tank is 50 ⁇ 70 °C, and the latter stage is cooled by normal temperature water.
  • the nominal thickness of the first sheath layer is not less than 1.4mm.
  • the step 2) further includes:
  • Step 2.2 Twist the multiple cables prepared in step 2.1). After the twisting, the metal shielding layer of each cable is the same conduction;
  • the step 3) further includes:
  • the metal armor layer is a metal wire armor layer or a metal tape armor layer; the average wrapping rate of the second wrapping tape layer is not less than 15%, and the minimum overlap is not less than 5 mm;
  • the second sheath layer is extruded outside the second wrapping tape layer and is extruded from medium density polyethylene or high density polyethylene.
  • the process requirements include:
  • the temperature distribution of each zone of the extruder is: the temperature range of the first zone is 170 °C ⁇ 180 °C, the temperature range of the second zone, the third zone and the fourth zone is 175 °C ⁇ 185 °C, the fifth zone,
  • the temperature range of the six zones is 180 °C -190 °C, among which: the first zone is the feeding section, the second zone, the third zone and the fourth zone are the plasticizing section, and the fifth zone and the sixth zone are the homogenizing section;
  • the temperature of the head unit of the extruder is: the temperature range of the neck is 185-195 ° C, the temperature range of the head is 185-195 ° C, and the temperature range of the die is 185-195 ° C;
  • the jacket should be cooled in stages.
  • the water temperature of the cooling water tank in the first stage should be 50 ⁇ 70 °C, and the other sections should use normal temperature water.
  • the metal armor layer is a metal belt wrapped armor layer, and the metal belt is a galvanized steel belt or a stainless steel belt;
  • the nominal thickness of the metal strip is 0.5mm or 0.8mm, the wrapping gap is not more than 50% of the width of the metal strip, and the gap of the inner metal strip is covered by the part of the outer metal strip near the middle;
  • the metal armor layer is a metal wire wrapped armor layer, and the metal wire is galvanized steel wire or stainless steel wire;
  • the wrapping tape of the second wrapping tape layer is a non-woven fabric with a nominal thickness of 0.2 mm or 0.3 mm.
  • the nominal thickness of the second sheath layer is not less than 1.8 mm.
  • the structure of the cable core is that the conductor wraps the first layer of water-blocking expansion tape, semi-conductive conductor shielding layer, water-resistant tree cross-linked polyethylene insulation layer and semi-conductive insulation shielding layer to form a wire core;
  • the core is wrapped with a second layer of water-blocking expansion strip and a metal shield to form the cable core;
  • the conductor is a circular longitudinal water-blocking conductor composed of metal monofilament and water-blocking material tightly twisted;
  • the first layer of water-blocking expansion band material and the second layer of water-blocking expansion band material are both composed of one or more layers of semi-conducting resistance water tape wrapped around, and the average overlap rate of the wrapped around is not less than 15%;
  • the first wrapping tape layer is composed of wrapping tape wrapping, the wrapping tape is a double-sided insulating water blocking tape, the average overlapping rate of the wrapping is not less than 15%, the minimum overlap is not less than 5mm; double-sided insulating water blocking
  • the nominal thickness of the belt is at least 0.35mm;
  • the radial waterproof layer is longitudinally wrapped by the aluminum-plastic composite tape along the axis direction of the cable core outside the first wrapping tape layer; the thickness of the aluminum-plastic composite tape is not less than 0.25 mm, and the plastic parts of the left and right sides of the aluminum-plastic composite tape Hot melt bonding, the overlapping part is not less than 5mm;
  • the sheath layer is composed of extruded polyethylene sheath material outside the radial waterproof layer.
  • a multi-core longitudinal radial water-blocking hydraulic power cable manufactured by the above method includes a cable core, and a first wrapping tape layer, a radial waterproof layer, an inner sheath layer, and a metal armor that are sequentially wrapped outside the cable core Layer, second wrapping tape layer and outer sheath layer;
  • the cable core is formed by twisting a plurality of cores, and the structure of any core is: the conductor is sequentially wrapped with a first layer of water-blocking expansion tape, a semi-conductive conductor shielding layer, a water-resistant tree-shaped cross-linked polyethylene insulation layer, The semi-conductive insulating shielding layer, the second layer of water-swellable tape and the metal shielding layer; the cores in the first wrapping layer are filled and filled;
  • the conductor is a circular longitudinal water-blocking conductor composed of metal monofilament and water-blocking material tightly twisted;
  • the first layer of water-blocking expansion band material and the second layer of water-blocking expansion band material are both composed of one or more layers of semi-conducting resistance water tape wrapped around, and the average overlap rate of the wrapped around is not less than 15%;
  • the first wrapping tape layer is composed of wrapping tape wrapping, the wrapping tape is a double-sided insulating water blocking tape, the average overlapping rate of the wrapping is not less than 15%, the minimum overlap is not less than 5mm; double-sided insulating water blocking
  • the nominal thickness of the belt is at least 0.35mm;
  • the inner sheath layer is formed by extruding polyethylene sheath material outside the radial waterproof layer;
  • the average wrapping rate of the second wrapping tape layer is not less than 15%, and the minimum overlap is not less than 5mm;
  • the outer sheath layer is formed by extruding and wrapping a polyvinyl chloride sheath material, a polyethylene sheath material or a low-smoke halogen-free fuel barrier on the second wrapping tape layer.
  • the filled material is a water-blocking swelling material (such as a water-blocking filler rope). After filling, the cable core remains round and ensures that the metal shields of the individual cores are in electrical contact.
  • the invention has the following beneficial effects:
  • the conductor layer, metal shielding layer and other structural layers of the cable that need to perform conductive functions are longitudinally water-blocking, even if the cable is laid and operated in a humid environment, it can effectively prevent the cable from absorbing water and keep the core and metal
  • the drying of the shield prevents oxidation of the conductor and metal shield.
  • the use of a longitudinal water-blocking structure layer ensures safe and stable operation of the cable in a humid environment, which means that the medium voltage cable has a lower failure replacement rate and reduces hidden costs due to cable failure.
  • the use of the radial waterproof layer of the cable makes it more difficult for moisture and moisture to enter the metal shield, insulation and conductor parts, even if the outer jacket is slightly damaged or laid in shallow water (water depth up to 5m).
  • the use of longitudinal radial resistance water pressure power cables can greatly improve the service life of medium voltage power cables, usually not less than 30 years, which is more than 2 times longer than that of ordinary medium voltage power cables, which means that the application of longitudinal After blocking the water pressure power cable, it greatly saves the consumption of copper, aluminum, polyethylene and other materials in the product life cycle, effectively reduces the breakdown rate of the cable, and effectively promotes the green development of the cable industry.
  • the three-layer co-extrusion production ensures the cleanliness of cable insulation, reduces impurities and pores in the insulation, and ensures the effectiveness of cable insulation for long-term operation.
  • FIG. 1 is a schematic view of a radial cross section of a three-core cable of an embodiment
  • FIG. 2 is a schematic radial cross-sectional view of one core of the three-core cable of the embodiment
  • FIG. 3 is a schematic view of a radial cross-section of a single-core cable of an embodiment
  • a manufacturing method and cable for longitudinal radial resistance water pressure power cable specifically:
  • a longitudinal radial resistance water pressure power cable the steps include: 1) manufacturing a wire core; 2) manufacturing a cable core; 3) manufacturing a protective layer, characterized by
  • the step 1) includes:
  • the step 2) includes:
  • step 1) the cable is wrapped with a second layer of water-resistant expansion tape and a metal shield layer in sequence;
  • the step 3) includes:
  • step 2) the first cable wrap layer, the radial waterproof layer and the first sheath layer are wrapped around the prepared cable in sequence;
  • the conductor is a circular longitudinal water-blocking conductor formed by tightly twisting the metal monofilament and the water-blocking material;
  • the step 1.2) includes:
  • the first layer of water-blocking expansion strip is composed of one or more layers of semi-conducting resistance water-wrap, and the average overlap rate of the wrap is not less than 15%;
  • the semi-conducting conductor shielding layer, water-resistant tree cross-linked polyethylene insulation layer and semi-conducting insulation shielding layer are composed of extruded corresponding cable materials;
  • the second layer of water-blocking expansion strip is composed of one or more layers of semiconducting resistance water-wrap, and the average overlap rate of the wrap is not less than 15%;
  • the first wrapping tape layer is composed of wrapping tape wrapping, the wrapping tape is a double-sided insulating water blocking tape, the average overlapping rate of the wrapping is not less than 15%, the minimum overlap is not less than 5mm; double-sided insulating water blocking
  • the nominal thickness of the belt is at least 0.35mm;
  • the radial waterproof layer is composed of an aluminum-plastic composite tape longitudinally wrapped around the first wrapping tape layer along the axis direction of the cable core, and the requirements include:
  • the thickness of the aluminum-plastic composite tape is not less than 0.25mm, the plastic parts of the left and right sides of the aluminum-plastic composite tape are hot-melt bonded, and the overlapping part is not less than 5mm;
  • Thermocouples are used to heat the aluminum-plastic composite tape in the horn die, wire stabilizing die, and sizing die to make the plastic film soften and sticky, so that the two longitudinal edges overlap and are subsequently extruded with polyethylene
  • the sheath is tightly bonded, and the temperature of the three molds is set to 120 °C, 140 °C, and 160 °C in sequence;
  • the first sheath layer is extruded polyethylene sheath material outside the radial waterproof layer (in actual production, linear low density polyethylene, medium density polyethylene or high density polyethylene sheath material can be selected, depending on the material , Just fine-tune the production line speed), process requirements include:
  • the temperature of the head unit of the extruder is: the temperature range of the neck is 185-195 ° C, the temperature range of the head is 185-195 ° C, and the temperature range of the die is 185-195 ° C;
  • the cooling is by cold water.
  • the metal shielding layer is a copper tape shielding layer, and the copper tape shielding layer is composed of one or more layers of overlapping soft copper tape; the average covering rate of the wrapping is not less than 15%, and the minimum covering rate is not less than 5 %, The nominal thickness of the copper strip is not less than 0.12mm;
  • the nominal thickness of the first sheath layer is not less than 1.4mm.
  • the step 2) further includes:
  • Step 2.2 Twist the multiple cables prepared in step 2.1). After the twisting, the metal shielding layer of each cable is the same conduction;
  • the step 3) further includes:
  • the plurality of wires around the first cladding step 2.1) are filled and filled between the cables;
  • the metal armor layer is a metal wire armor layer or a metal tape armor layer; the average wrapping rate of the second wrapping tape layer is not less than 15%, and the minimum overlap is not less than 5 mm;
  • the second sheath layer is extruded and wrapped with medium-density polyethylene or high-density polyethylene sheath material around the second wrapping tape layer, and the process requirements include:
  • the temperature distribution of each zone of the extruder is: the temperature range of zone 1 is 175 °C, the temperature range of zones 2, 3 and 4 is 180 °C, and the temperature range of zones 5 and 6 is 185 °C, of which: the first zone is the feeding section, the second zone, the third zone and the fourth zone are the plasticizing section, and the fifth zone and the sixth zone are the homogenizing section;
  • the temperature of the head unit of the extruder is: the temperature range of the neck is 190 ° C, the temperature range of the head is 190 ° C, and the temperature range of the die is 190 ° C; (in actual operation, there can be ⁇ 5 ° C operating margin).
  • the jacket should be cooled in stages.
  • the water temperature of the cooling water tank in the first stage should be 50 ⁇ 70 °C, and the other sections should use normal temperature water.
  • the metal armor layer is a metal belt wrapped armor layer, and the metal belt is a galvanized steel belt or a stainless steel belt;
  • the nominal thickness of the metal strip is 0.5mm or 0.8mm, the wrapping gap is not more than 50% of the width of the metal strip, and the gap of the inner metal strip is covered by the part of the outer metal strip near the middle;
  • the metal armor layer is a metal wire wrapped armor layer, and the metal wire is galvanized steel wire or stainless steel wire;
  • the nominal diameter of the metal wire is 1.25mm, 1.6mm, 2.0mm, 2.5mm or 3.15mm; the total armor gap of the metal wire armor layer is not greater than the diameter of a metal wire, and the ratio of the pitch diameter of the metal wire wrapping is 12 to 16 times;
  • the wrapping tape of the second wrapping tape layer is a non-woven fabric with a nominal thickness of 0.2 mm or 0.3 mm.
  • the nominal thickness of the second sheath layer is not less than 1.8 mm.
  • the multi-core (three-core in this example) longitudinal radial water-blocking power cable produced by this method includes a cable core, and a first winding clad layer and Waterproof layer, first sheath layer, metal armor layer, second wrapping tape layer and second sheath layer;
  • the cable core is formed by twisting three cores. As shown in FIG. 2, the structure of any core is: the conductor wraps the first layer of water-blocking expansion strip, the semi-conductive conductor shield layer, and the water-resistant tree cross-linked polymer Vinyl insulation layer, semi-conductive insulation shielding layer, second layer of water-blocking expansion tape and metal shielding layer; each core in the first wrapping tape layer is filled and filled;
  • the conductor is a circular longitudinal water-blocking conductor composed of metal monofilament and water-blocking material tightly twisted;
  • the first layer of water-blocking expansion strips and the second layer of water-blocking expansion strips are both composed of one or more layers of semi-conducting resistive hoses wrapped around, the average overlap rate of the wrapping is not less than 15% ;
  • the first wrapping tape layer is composed of wrapping tape wrapping, the wrapping tape is a double-sided insulating water blocking tape, the average overlapping rate of the wrapping is not less than 15%, the minimum overlap is not less than 5mm; double-sided insulating water blocking
  • the nominal thickness of the belt is at least 0.35mm;
  • the radial waterproof layer is longitudinally wrapped by the aluminum-plastic composite tape along the axis direction of the cable core outside the first wrapping tape layer; the thickness of the aluminum-plastic composite tape is not less than 0.25 mm, and the plastic parts of the left and right sides of the aluminum-plastic composite tape Hot melt bonding, the overlapping part is not less than 5mm;
  • the first sheath layer is composed of extruded polyethylene sheath material outside the radial waterproof layer;
  • the metal armor layer is a metal wire armor layer or a metal tape armor layer
  • the average wrapping rate of the second wrapping tape layer is not less than 15%, and the minimum overlap is not less than 5mm;
  • the second sheathing layer is formed by extruding a polyvinyl chloride sheathing material, polyethylene sheathing material or low-smoke halogen-free fuel around the second wrapping tape layer.
  • a single-core longitudinal radial water-blocking power cable manufactured by the above method includes a cable core, and a first wrapping tape layer, a radial waterproof layer, and a sheath layer sequentially wrapped around the cable core;
  • the structure of the cable core is that the conductor wraps the first layer of water-blocking expansion tape, semi-conductive conductor shielding layer, water-resistant tree cross-linked polyethylene insulation layer and semi-conductive insulation shielding layer to form a wire core;
  • the core is wrapped with a second layer of water-blocking expansion strip and a metal shield to form the cable core;
  • the first layer of water-blocking expansion band material and the second layer of water-blocking expansion band material are both composed of one or more layers of semi-conducting resistance water tape wrapped around, and the average overlap rate of the wrapped around is not less than 15%;
  • the first wrapping tape layer is composed of wrapping tape wrapping, the wrapping tape is a double-sided insulating water blocking tape, the average overlapping rate of the wrapping is not less than 15%, the minimum overlap is not less than 5mm; double-sided insulating water blocking
  • the nominal thickness of the belt is at least 0.35mm;
  • the radial waterproof layer is longitudinally wrapped by the aluminum-plastic composite tape along the axis direction of the cable core outside the first wrapping tape layer; the thickness of the aluminum-plastic composite tape is not less than 0.25 mm, and the plastic parts of the left and right sides of the aluminum-plastic composite tape Hot melt bonding, the overlapping part is not less than 5mm;
  • the sheath layer is composed of extruded polyethylene sheath material outside the radial waterproof layer.
  • the nominal cross-sectional area of the copper wire shield is determined according to the actual fault current capacity.
  • the radial waterproof layer is an aluminum-plastic composite tape with a nominal thickness of at least 0.25mm, which is longitudinally wrapped around the cable core. The plastic on the aluminum-plastic composite tape is melted at a high temperature and bonded under the action of a mold. The overlapping overlap is not less than 5mm.
  • the sheath material of the first sheath layer is a polyethylene sheath, which is produced immediately after the radial waterproof layer is coated to ensure that the first sheath layer and the radial waterproof layer are closely adhered.
  • the filling is a water-resistant filling rope.
  • the metal armor layer complies with the relevant requirements of IEC 60502-2: 2014.
  • the jacket materials of the first and second jacket layers are compatible with the operating temperature of the cable.
  • the first and second jacket layers conform to the relevant requirements of IEC60502-2.
  • the performance parameters of the longitudinal radial water-blocking cable created by the present invention are as follows:
  • Heating cycle test The heating cycle lasts for at least 8h. During each heating process, the conductor temperature is maintained at 95 ° C to 100 ° C for at least 2h, and then the air is naturally cooled for at least 3h so that the conductor temperature does not exceed the ambient temperature by 10 ° C. Repeat the cycle 20 times. After the 20th cycle, a partial discharge test was conducted without any measurable discharge exceeding the declared sensitivity (5pC or better).
  • the tensile strength before aging is not less than 12.5Mpa, and the elongation at break is not less than 200%; after aging, the change rate of tensile strength is up to ⁇ 25%, and the change rate of elongation at break is up to ⁇ 25%.
  • Radial water blocking performance Radial waterproof test is carried out in accordance with the requirements of Article 10 of GB / T 28247. After the cable sample is immersed in water for 72h, the insulating surface of the split sample should be dry; the aluminum-plastic composite tape is adhered after being wrapped longitudinally The junction is complete and tight, the cable core is round and flat, and it is not empty. Carry out the peel strength test of the overlap of the aluminum-plastic composite tape according to the provisions of IEC 60840 Appendix G.
  • the minimum value is not less than 0.5N / mm;
  • the vinyl sheath is tightly bonded, the cable has a round appearance, the surface is smooth and the color is uniform, and the peel strength test between the aluminum-plastic composite tape and the polyethylene sheath material is carried out according to the provisions of IEC 60840 Appendix G.
  • the minimum value is not less than 0.5N / mm.
  • both the longitudinal radial water-blocking cable conductor and the metal shielding layer created by the present invention have longitudinal water-blocking characteristics
  • the aluminum-plastic composite tape serves as a longitudinal water-blocking layer, which effectively reduces the breakdown failure rate of the cable, even It can also operate safely and steadily for a long time in a humid environment, which greatly saves the consumption of copper, aluminum, polyethylene and other materials during the product life cycle, and strongly promotes the green development of the cable industry.

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Abstract

一种纵向径向阻水中压电力电缆的制造方法，步骤包括1)制造线芯；2)制造缆芯；3)制造防护层；步骤1)包括：制备导体；在导体外依次包裹第一层阻水膨胀带材、半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层；在步骤1)制得线缆外依次包裹第二层阻水膨胀带材和金属屏蔽层；在步骤2)制得线缆外依次包裹第一绕包带层、径向防水层和第一护套层。第一层阻水膨胀带材是由半导电阻水带绕包构成；半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层是挤包构成；第二层阻水膨胀带材是由半导电阻水带绕包构成；第一绕包带层是由绕包带绕包构成；径向防水层是由铝塑复合带沿缆芯的轴线方向纵包在第一绕包带层外构成。

Description

一种纵向径向阻水中压电力电缆的制造方法及电缆 技术领域
本发明创造涉及电缆技术领域，具体是有关于一种多芯纵向径向阻水中压电力电缆的制造方法及电缆。
背景技术
电缆分布在各个角落，安装敷设、使用环境千差万别。电缆到施工现场后，一般露天摆放，去除封头帽后一旦密封不好，难免会有水汽渗入电缆；电缆敷设时，需经常穿越道路、桥梁和涵洞等，由于天气或者地理等其他原因，电缆四周时常积聚许多的水，电缆头制作过程中，长时暴露或者施工人员疏忽，不可避免的会出现电缆头浸入水中的情况；在牵引和穿管时，有时也会发生护套被刮坏现象，当使用机械牵引时，这种现象尤为突出；在电缆正常运行时，电缆如果因为某种外部原因发生击穿、断裂等严重故障，电缆也会进水。有水分浸入电缆，就容易产生水树，会严重降低电缆的电气性能，最终导致电缆击穿，影响电网安全稳定运行；电缆直接进水，引起钢带、铜带等金属层腐蚀，绝缘性能下降，会发生单相或者三相故障，甚至爆炸伤人。
随着社会发展，对电网的安全稳定运行提出了更高的要求，尤其是在香港、澳门、新加坡等经济发达的临海国家或地区，电缆长期敷设于潮湿环境中，同时停电一秒就意味着巨大的经济损失。
发明内容
本发明创造的目的在于提供一种有效降低电缆的击穿故障率的纵向径向阻水中压电力电缆。
为达上述目的，本发明创造提出一种纵向径向阻水中压电力电缆的制造方法及电缆，具体为：
一种纵向径向阻水中压电力电缆的制造方法，步骤包括：1)制造线芯；2)制造缆芯；3)制造防护层。
所述步骤1)包括：
1.1)制备导体；
1.2)在导体外依次包裹第一层阻水膨胀带材、半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层；
所述步骤2)包括：
2.1)在步骤1)制得线缆外依次包裹第二层阻水膨胀带材和金属屏蔽层；
所述步骤3)包括：
3.1)在步骤2)制得线缆外依次包裹第一绕包带层、径向防水层和第一护套层；
所述步骤1.1)中，导体是由金属单丝与阻水材料紧压绞合构成的圆形纵向阻水导体；
所述步骤1.2)包括：
1.2.1)第一层阻水膨胀带材是由一层或者多层半导电阻水带绕包构成，绕包的平均重叠率不小于15％；
1.2.2)半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层是挤包相应电缆料构成；
所述步骤2.1)中，第二层阻水膨胀带材是由一层或者多层半导电阻水带绕包构成，绕包的平均重叠率不小于15％；
所述步骤3.1)中，
所述第一绕包带层是由绕包带绕包构成，绕包带是双面绝缘阻水带，绕包的平均重叠率 不小于15％，最小重叠不小于5mm；双面绝缘阻水带的标称厚度至少是0.35mm；
所述径向防水层是由铝塑复合带沿缆芯的轴线方向纵包在第一绕包带层外构成，要求包括：
a、铝塑复合带的厚度是不小于0.25mm，铝塑复合带左右两边的塑料部分热熔粘接起来，重叠部分不小于5mm；
b、模具要求：沿生产线前进方向，依次设置纵包套管、喇叭膜、稳线模和定径模，最后送入第一护套层的挤塑机头；
为了降低生产过程中的断带几率、纵包完全紧密、纵包后电缆外观圆整：
纵包喇叭模出口直径＝线缆直径+(2.0～2.5)mm；稳线模出口直径＝电线缆直径+(1.5～2.0)mm；定径模出口直径＝线缆直径+(1.0～1.5)mm；
在喇叭模、稳线模、定径模中均采用热电偶对铝塑复合带进行加热，使其塑料覆膜软化具有黏性，以便两条纵向边缘搭盖、且与后续挤出的聚乙烯护套紧密粘接，三个模具温度依次设定为120℃、140℃和160℃；
分别在三个模具之前各有一个热电吹风装置，对准两条纵向边缘搭接处的缝隙，对覆膜进行加热软化使其具有黏性，加热温度依次设定为140℃、160℃和160℃；
调整线缆前进的线速度较无纵包铝塑复合带时慢约30％～50％，具体根据电缆外径及挤出机生产速度进行调整；
最终在定径模的作用下，两条纵向边缘完全、紧密粘接，粘接后铝塑复合带平整，构成管状结构包在第一绕包带层外；
所述第一护套层是在径向防水层外挤包聚乙烯护套料，工艺要求包括：
自进料到出料方向，(机身六段加热)挤塑机的机身各区温度分布为：一区温度范围是170℃～180℃；二区、三区和四区温度范围都是是175℃～185℃；五区和六区温度范围都是180℃～190℃；
其中：一区为入料段，二区、三区和四区为塑化段，五区、六区为均化段；
挤塑机的机头单元温度为：机颈的温度范围是185～195℃、机头的温度范围是185～195℃、模口的温度范围是185～195℃；
护套应采用分段冷却，第一段冷却水槽水温为50～70℃，其后均采用常温水。
所述导体的金属单丝是由铜单丝或铝单丝；阻水材料是阻水膨胀纱、阻水膨胀带或阻水膨胀粉。
所述步骤1.2.2)中，半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层是三层共挤相应电缆料构成，工艺要求为：
半导电导体屏蔽层(八段加热)挤塑机温度依次设定为：
一区60℃，二区95℃、三区105℃、四区106℃、五区106℃、机颈106℃、机头106℃和模口106℃，温度设定偏差±5℃；
抗水树型交联聚乙烯绝缘层(八段加热)挤塑机温度依次设定为一区80℃、二区116℃、三区118℃、四区120℃、五区120℃、机颈120℃、机头120℃和1模口20℃，温度设定偏差±5℃；
半导电绝缘屏蔽层(八段加热)挤塑机温度依次设定为一区60℃、二区95℃、三区105℃、四区112℃、五区112℃、机颈112℃、机头112℃和模口112℃，温度设定偏差±5℃；
冷却是采用冷水冷却；
步骤1.2.2)中挤塑剂，一区为入料段，二区和三区为塑化段，四区和五区为均化段。
金属屏蔽层是铜丝屏蔽层；铜丝屏蔽层的外表面由反向绕包的铜丝或铜带扎紧；铜丝屏蔽层的相邻铜丝的平均间隙不大于4mm；
或者，金属屏蔽层是铜带屏蔽层，铜带屏蔽层是一层或者多层重叠绕包的软铜带构成； 绕包的平均搭盖率不小于15％，且最小搭盖率不小于5％，铜带标称厚度不小于0.12mm；
第一护套层的标称厚度不小于1.4mm。
所述步骤2)还包括：
步骤2.2)把多根步骤2.1)制得线缆进行绞合，绞合后，各根线缆的金属屏蔽层是相同导通的；
所述步骤3)还包括：
步骤3.2)在步骤3.1)制得线缆外依次包裹金属铠装层、第二绕包带层和第二护套层；
所述步骤3.1)中，第一绕包带层的多根步骤2.1)制得线缆之间填满填充；
所述步骤3.2)中，金属铠装层是金属丝铠装层或金属带铠装层；所述第二绕包带层的绕包平均重叠率都不小于15％，最小重叠不小于5mm；
所述第二护套层是在第二绕包带层外挤包聚乙烯护套料(优选是中密度聚乙烯或高密度聚乙烯护套料)，工艺要求包括：
自进料到出料方向，挤塑机的机身各区温度分布为：一区温度范围是170℃～180℃；二区、三区和四区温度范围都是175℃～185℃；五区和六区温度范围都是180℃～190℃，其中：一区为入料段，二区、三区、四区为塑化段，五区、六区为均化段；
挤塑机的机头单元温度为：机颈温度范围是185～195℃、机头温度范围是185～195℃、模口温度范围是185～195℃；
护套应采用分段冷却，第一段冷却水槽水温为50～70℃，其后段均采用常温水冷却。
金属屏蔽层是铜丝屏蔽层；铜丝屏蔽层的外表面由反向绕包的铜丝或铜带扎紧；铜丝屏蔽层的相邻铜丝的平均间隙不大于4mm；
或者，金属屏蔽层是铜带屏蔽层，铜带屏蔽层是一层或者多层重叠绕包的软铜带构成；绕包的平均搭盖率不小于15％，且最小搭盖率不小于5％，铜带标称厚度不小于0.12mm；
第一护套层的标称厚度不小于1.4mm。
对于多线芯电缆来说，所述步骤2)还包括：
步骤2.2)把多根步骤2.1)制得线缆进行绞合，绞合后，各根线缆的金属屏蔽层是相同导通的；
所述步骤3)还包括：
步骤3.2)在步骤3.1)制得线缆外依次包裹金属铠装层、第二绕包带层和第二护套层；
所述步骤3.1)中，第一绕包带层的多根步骤2.1)制得线缆之间填满填充；
所述步骤3.2)中，金属铠装层是金属丝铠装层或金属带铠装层；所述第二绕包带层的绕包平均重叠率都不小于15％，最小重叠不小于5mm；
所述第二护套层是在第二绕包带层外挤包是挤包中密度聚乙烯或高密度聚乙烯，工艺要求包括：
自进料到出料方向，挤塑机的机身各区温度分布为：一区温度范围是170℃～180℃，二区、三区、四区温度范围是175℃～185℃，五区、六区温度范围是180℃-190℃，其中：一区为入料段，二区、三区、四区为塑化段，五区、六区为均化段；
挤塑机的机头单元温度为：机颈为温度范围是185～195℃℃、机头为温度范围是185～195℃、模口为温度范围是185～195℃；
护套应采用分段冷却，第一段冷却水槽水温为50～70℃，其它段均采用常温水。
所述金属铠装层是金属带绕包铠装层，金属带是镀锌钢带或不锈钢带；
金属带的标称厚度为0.5mm或0.8mm，绕包间隙不大于金属带宽度的50％，且内层金属带的间隙被外层金属带的靠近中间的部位所覆盖；
或者，所述金属铠装层是金属丝绕包铠装层，金属丝是镀锌钢丝或不锈钢丝；
金属丝的标称直径为1.25mm、1.6mm、2.0mm、2.5mm或3.15mm；金属丝铠装层的铠装总间隙不大于一根金属丝的直径，金属丝绕包的节径比是12～16倍；
第二绕包带层的绕包带是标称厚度为0.2mm或0.3mm的无纺布。
第二护套层的标称厚度不小于1.8mm。
一种上述方法制得的单芯纵向径向阻水中压电力电缆，包括缆芯，以及在缆芯外依次包裹的第一绕包带层、径向防水层和护套层；
所述缆芯的结构为：导体依次包裹第一层阻水膨胀带材、半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层构成线芯；在一根线芯外包裹第二层阻水膨胀带材和金属屏蔽层构成缆芯；
所述导体是由金属单丝与阻水材料紧压绞合构成的圆形纵向阻水导体；
所述第一层阻水膨胀带材和第二层阻水膨胀带材都是由一层或者多层半导电阻水带绕包构成，绕包的平均重叠率不小于15％；
所述第一绕包带层是由绕包带绕包构成，绕包带是双面绝缘阻水带，绕包的平均重叠率不小于15％，最小重叠不小于5mm；双面绝缘阻水带的标称厚度至少是0.35mm；
所述径向防水层是由铝塑复合带沿缆芯的轴线方向纵包在第一绕包带层外；铝塑复合带的厚度是不小于0.25mm，铝塑复合带左右两边的塑料部分热熔粘接起来，重叠部分不小于5mm；
护套层是在径向防水层外挤包聚乙烯护套料构成。
一种上述方法制得的多芯纵向径向阻水中压电力电缆，包括缆芯，以及在缆芯外依次包裹的第一绕包带层、径向防水层、内护套层、金属铠装层、第二绕包带层和外护套层；
所述缆芯是由多根线芯绞合构成，任一线芯的结构为：导体依次包裹第一层阻水膨胀带材、半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层、半导电绝缘屏蔽层、第二层阻水膨胀带材和金属屏蔽层；第一绕包带层内的各个线芯之间填满填充；
所述导体是由金属单丝与阻水材料紧压绞合构成的圆形纵向阻水导体；
所述第一层阻水膨胀带材和第二层阻水膨胀带材都是由一层或者多层半导电阻水带绕包构成，绕包的平均重叠率不小于15％；
所述第一绕包带层是由绕包带绕包构成，绕包带是双面绝缘阻水带，绕包的平均重叠率不小于15％，最小重叠不小于5mm；双面绝缘阻水带的标称厚度至少是0.35mm；
所述径向防水层是由铝塑复合带沿缆芯的轴线方向纵包在第一绕包带层外；铝塑复合带的厚度是不小于0.25mm，铝塑复合带左右两边的塑料部分热熔粘接起来，重叠部分不小于5mm；
所述内护套层是在径向防水层外挤包聚乙烯护套料构成；
所述金属铠装层是金属丝铠装层或金属带铠装层；
所述第二绕包带层的绕包平均重叠率都不小于15％，最小重叠不小于5mm；
所述外护套层是在第二绕包带层外挤包聚氯乙烯护套料、聚乙烯护套料或低烟无卤阻燃料构成。
填充的材料是阻水膨胀材料(例如阻水填充绳)，填充后缆芯保持圆整，并确保各个线芯的金属屏蔽层是电气接触的。
与现有技术相比，本发明创造具有以下有益效果：
1，本发明创造中，电缆的导体、金属屏蔽层等需执行导电功能的结构层均是纵向阻水的，即使电缆在潮湿环境中敷设、运行，能有效防止电缆吸水，保持线芯及金属屏蔽的干燥，防止导体和金属屏蔽氧化。当电缆意外断裂时，除去端头最多1.5m，可保证电缆导体、金属屏蔽层干燥，重新制作接头即可。纵向阻水结构层的使用保证电缆在潮湿环境下安全、稳定运行，意味着中压电缆更低的故障更换率，减少因电缆故障而产生的隐性成本。
2，本发明创造中，电缆径向防水层的使用使得水分、水汽更难以进入金属屏蔽层、绝缘及导体部分，即使外层护套有轻微损伤或在浅水(水深最多5m)中敷设。
同时，由于采用纵向径向阻水中压电力电缆，可以大大提高中压电力电缆的使用寿命，通常不低于30年，比普通中压电力电缆使用寿命增加2倍以上，这就意味着应用纵向阻水中压电力电缆以后，在产品生命周期内大大节约了铜、铝、聚乙烯等材料的消耗，有效降低电缆的击穿故障率，有力推进电缆行业绿色发展。
3，本发明创造中，电缆的绝缘材料为抗水树型交联聚乙烯，同时导体屏蔽、绝缘、绝缘屏蔽为三层共挤式生产。在潮湿的地方，电缆就容易产生水树，会严重降低电缆的电气性能，最终导致电缆击穿，影响电网安全稳定运行，抗水树型交联聚乙烯绝缘有效解决这一问题。
4，三层共挤式生产保证了电缆绝缘的洁净度，减少绝缘中的杂质、气孔，保证电缆绝缘长期运行的有效性。
附图说明
图1是实施例的三芯电缆的径向截面示意图；
图2是实施例的三芯电缆的一个线芯的径向截面示意图；
图3是实施例的单芯电缆的径向截面示意图；
图4是电缆的部分层状结构的斜切截面示意图(仅用来以示意径向防水层结构)；
图中：1导体、2第一层阻水膨胀带材、3半导电导体屏蔽层、4抗水树型交联聚乙烯绝缘层、5半导电绝缘屏蔽层、6第二层阻水膨胀带材、7金属屏蔽层、8填充、9第一绕包带层、10径向防水层、11第一护套层、12金属铠装层、13第二绕包带层、14第二护套层、15铝塑复合带的重叠部分。
具体实施方式
为了更了解本发明创造的技术内容，特举具体实施例并配合所附图式说明如下。
一种纵向径向阻水中压电力电缆的制造方法及电缆，具体为：
一种纵向径向阻水中压电力电缆，步骤包括：1)制造线芯；2)制造缆芯；3)制造防护层，其特征是
所述步骤1)包括：
1.1)制备导体；
1.2)在导体外依次包裹第一层阻水膨胀带材、半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层；
所述步骤2)包括：
2.1)在步骤1)制得线缆外依次包裹第二层阻水膨胀带材和金属屏蔽层；
所述步骤3)包括：
3.1)在步骤2)制得线缆外依次包裹第一绕包带层、径向防水层和第一护套层；
所述步骤1.1)中，导体是由金属单丝与阻水材料紧压绞合构成的圆形纵向阻水导体；
所述步骤1.2)包括：
1.2.1)第一层阻水膨胀带材是由一层或者多层半导电阻水带绕包构成，绕包的平均重叠率不小于15％；
1.2.2)半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层是挤包相应电缆料构成；
所述步骤2.1)中，第二层阻水膨胀带材是由一层或者多层半导电阻水带绕包构成，绕包的平均重叠率不小于15％；
所述步骤3.1)中，
所述第一绕包带层是由绕包带绕包构成，绕包带是双面绝缘阻水带，绕包的平均重叠率不小于15％，最小重叠不小于5mm；双面绝缘阻水带的标称厚度至少是0.35mm；
所述径向防水层是由铝塑复合带沿缆芯的轴线方向纵包在第一绕包带层外构成，要求包括：
a、铝塑复合带的厚度是不小于0.25mm，铝塑复合带左右两边的塑料部分热熔粘接起来，重叠部分不小于5mm；
b、模具要求：沿生产线前进方向，依次设置纵包套管、喇叭膜、稳线模和定径模，最后送入第一护套层的挤塑机头；
为了降低生产过程中的断带几率、纵包完全紧密、纵包后电缆外观圆整：
纵包喇叭模出口直径＝线缆直径+(2.0～2.5)mm；稳线模出口直径＝电线缆直径+(1.5～2.0)mm；定径模出口直径＝线缆直径+(1.0～1.5)mm；
在喇叭模、稳线模、定径模中均采用热电偶对铝塑复合带进行加热，使其塑料覆膜软化具有黏性，以便两条纵向边缘搭盖、且与后续挤出的聚乙烯护套紧密粘接，三个模具温度依次设定为120℃、140℃、160℃；
同时在三个模具之前各有一个热电吹风装置，对准两条纵向边缘搭接处的缝隙，对覆膜进行加热软化使其具有黏性，加热温度依次设定为140℃、160℃、160℃；
此时线缆前进的线速度较无纵包铝塑复合带时慢约30％～50％，具体根据电缆外径及挤出机生产速度进行调整；
最终在定径模的作用下，两条纵向边缘完全、紧密粘接，粘接后铝塑复合带平整，构成管状结构包在第一绕包带层外；
所述第一护套层是在径向防水层外挤包聚乙烯护套料(实际生产中，可选线性低密度聚乙烯或中密度聚乙烯或高密度聚乙烯护套料，根据材料不同，微调生产线速度即可)，工艺要求包括：
自进料到出料方向，挤塑机的机身各区温度分布为：一区温度范围是170℃～180℃，二区、三区、四区温度范围是175℃～185℃，五区、六区温度范围是180℃-190℃，其中：一区为入料段，二区、三区、四区为塑化段，五区、六区为均化段；
挤塑机的机头单元温度为：机颈为温度范围是185～195℃℃、机头为温度范围是185～195℃、模口为温度范围是185～195℃；
护套应采用分段冷却，第一段冷却水槽水温为50～70℃，其它段均采用常温水。
所述导体的金属单丝是由铜单丝或铝单丝；阻水材料是阻水膨胀纱、阻水膨胀带或阻水膨胀粉。
所述步骤1.2.2)中，半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层是三层共挤相应电缆料构成，(在工程中可以采用质量较为稳定的北欧化工或陶氏化学相应材料)，工艺要求为：
导体屏蔽挤塑机温度设定依次为60℃、95℃、105℃、106℃、106℃、106℃、106℃、106℃，温度设定偏差±5℃；
绝缘挤塑机温度设定依次为80℃、116℃、118℃、120℃、120℃、120℃、120℃、120℃，温度设定偏差±5℃；
绝缘屏蔽挤塑机温度设定依次为60℃、95℃、105℃、112℃、112℃、112℃、112℃、112℃，温度设定偏差±5℃；
(在实际运行时候，可以有±5℃偏差，但是，经过实践证明，温度偏离上述温度要求越少，产品质量越好，体现在内部的气泡、外表的光洁程度以及较小的加工应力等)。
冷却是采用冷水冷却。
金属屏蔽层是铜丝屏蔽层；铜丝屏蔽层的外表面由反向绕包的铜丝或铜带扎紧；铜丝屏蔽层的相邻铜丝的平均间隙不大于4mm；
或者，金属屏蔽层是铜带屏蔽层，铜带屏蔽层是一层或者多层重叠绕包的软铜带构成；绕包的平均搭盖率不小于15％，且最小搭盖率不小于5％，铜带标称厚度不小于0.12mm；
第一护套层的标称厚度不小于1.4mm。
对于多线芯电缆来说，所述步骤2)还包括：
步骤2.2)把多根步骤2.1)制得线缆进行绞合，绞合后，各根线缆的金属屏蔽层是相同导通的；
所述步骤3)还包括：
步骤3.2)在步骤3.1)制得线缆外依次包裹金属铠装层、第二绕包带层和第二护套层；
所述步骤3.1)中，第一绕包带层的多根步骤2.1)制得线缆之间填满填充；
所述步骤3.2)中，金属铠装层是金属丝铠装层或金属带铠装层；所述第二绕包带层的绕包平均重叠率都不小于15％，最小重叠不小于5mm；
所述第二护套层是在第二绕包带层外挤包中密度聚乙烯或高密度聚乙烯护套料，工艺要求包括：
自进料到出料方向，挤塑机的机身各区温度分布为：一区温度范围是175℃，二区、三区、四区温度范围是180℃，五区、六区温度范围是185℃，其中：一区为入料段，二区、三区、四区为塑化段，五区、六区为均化段；
挤塑机的机头单元温度为：机颈为温度范围是190℃、机头为温度范围是190℃、模口为温度范围是190℃；(在实际运行时候，可以有±5℃作业余量，但是，经过实践证明，温度偏离上述温度要求越少，产品质量越好，体现在内部的气泡、外表的光洁程度以及较小的加工应力等)。
护套应采用分段冷却，第一段冷却水槽水温为50～70℃，其它段均采用常温水。
所述金属铠装层是金属带绕包铠装层，金属带是镀锌钢带或不锈钢带；
金属带的标称厚度为0.5mm或0.8mm，绕包间隙不大于金属带宽度的50％，且内层金属带的间隙被外层金属带的靠近中间的部位所覆盖；
或者，所述金属铠装层是金属丝绕包铠装层，金属丝是镀锌钢丝或不锈钢丝；
金属丝的标称直径为1.25mm、1.6mm、2.0mm、2.5mm或3.15mm；金属丝铠装层的铠装总间隙不大于一根金属丝的直径，金属丝绕包的节径比是12～16倍；
第二绕包带层的绕包带是标称厚度为0.2mm或0.3mm的无纺布。
第二护套层的标称厚度不小于1.8mm。
如图1，本方法制得的多线芯(本例是三线芯)纵向径向阻水中压电力电缆，其结构包括缆芯，以及在缆芯外依次包裹的第一绕包带层、径向防水层、第一护套层、金属铠装层、第二绕包带层和第二护套层；
所述缆芯是由3根线芯绞合构成，如图2，任一线芯的结构为：导体依次包裹第一层阻水膨胀带材、半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层、半导电绝缘屏蔽层、第二层阻水膨胀带材和金属屏蔽层；第一绕包带层内的各个线芯之间填满填充；
所述导体是由金属单丝与阻水材料紧压绞合构成的圆形纵向阻水导体；
所述第一层阻水膨胀带材和第二层阻水膨胀带材都是由一层或者多层半导电阻水带绕包构成，绕包的平均重叠率不小于15％，绕包平服；
所述第一绕包带层是由绕包带绕包构成，绕包带是双面绝缘阻水带，绕包的平均重叠率不小于15％，最小重叠不小于5mm；双面绝缘阻水带的标称厚度至少是0.35mm；
所述径向防水层是由铝塑复合带沿缆芯的轴线方向纵包在第一绕包带层外；铝塑复合带的厚度是不小于0.25mm，铝塑复合带左右两边的塑料部分热熔粘接起来，重叠部分不小于5mm；
所述第一护套层是在径向防水层外挤包聚乙烯护套料构成；
所述金属铠装层是金属丝铠装层或金属带铠装层；
所述第二绕包带层的绕包平均重叠率都不小于15％，最小重叠不小于5mm；
所述第二护套层是在第二绕包带层外挤包聚氯乙烯护套料、聚乙烯护套料或低烟无卤阻燃料构成。
如图3，一种上述方法制得的单芯纵向径向阻水中压电力电缆，包括缆芯，以及在缆芯外依次包裹的第一绕包带层、径向防水层和护套层；
所述缆芯的结构为：导体依次包裹第一层阻水膨胀带材、半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层构成线芯；在一根线芯外包裹第二层阻水膨胀带材和金属屏蔽层构成缆芯；
所述导体是由金属单丝与阻水材料紧压绞合构成的圆形纵向阻水导体；
所述第一层阻水膨胀带材和第二层阻水膨胀带材都是由一层或者多层半导电阻水带绕包构成，绕包的平均重叠率不小于15％；
所述第一绕包带层是由绕包带绕包构成，绕包带是双面绝缘阻水带，绕包的平均重叠率不小于15％，最小重叠不小于5mm；双面绝缘阻水带的标称厚度至少是0.35mm；
所述径向防水层是由铝塑复合带沿缆芯的轴线方向纵包在第一绕包带层外；铝塑复合带的厚度是不小于0.25mm，铝塑复合带左右两边的塑料部分热熔粘接起来，重叠部分不小于5mm；
护套层是在径向防水层外挤包聚乙烯护套料构成。
在工程实践中，铜丝屏蔽的标称截面积根据实际的故障电流容量确定。径向防水层是标称厚度至少0.25mm的铝塑复合带纵包在缆芯外，铝塑复合带上的塑料在高温下熔融后在模具的作用下粘接起来，包覆重叠部分不小于5mm。第一护套层的护套料是聚乙烯护套，在径向防水层包覆后立即生产，保证第一护套层与径向防水层紧密粘连。填充是阻水填充绳，填充后缆芯保持圆整，并确保三个线芯的金属屏蔽层电气接触。金属铠装层符合IEC 60502-2：2014的相关要求。第一、二护套层的护套料与电缆运行温度相适应，第一、二护套层符合IEC60502-2的相关要求。
经过检测，本发明创造的纵向径向阻水中压电缆的性能参数如下：
1、局部放电试验：无任何超过声明灵敏度(5pC或更优)的可测放电。
2、弯曲试验及随后的局部放电试验：弯曲半径15(D+d)±5％，其中D为成品电缆外径，d为导体外径，弯曲三次；随后的局部放电试验，无任何超过声明灵敏度(5pC或更优)的可测放电。
3、加热循环试验：加热循环持续至少8h，每一加热过程中，导体温度95℃～100℃下维持至少2h，随后空气中自然冷却至少3h，使导体温度不超过环境温度10℃。重复循环20次。第20次循环后，进行局部放电试验，无任何超过声明灵敏度(5pC或更优)的可测放电。
4、冲击电压试验及随后的工频电压试验：导体温度95℃～100℃，施加符合IEC 60502-2要求的冲击电压，电缆不击穿；在冲击电压试验后，在室温下进行符合IEC 60502-2要求工频电压试验15min，绝缘不击穿。
5、绝缘机械性能：老化前抗张强度不小于12.5Mpa，断裂伸长率不小于200％；老化后，抗张强度变化率最大±25％，断裂伸长率变化率最大±25％。
6、纵向阻水性能：按照IEC60502-2：2014附录F的规定进行透水试验，电缆样品中部剖开至导体，把20±10℃的水在5min内注入管内，使得管子中水位高于电缆中心轴线1m，试样放置24h,然后对试样进行10次加热循环，每次循环持续8h，整个试验期间，电缆试样两端头的导体、金属屏蔽层内/外、填充(三线芯)无水分渗出。
7、径向阻水性能：按照GB/T 28247第10条要求进行径向防水试验，电缆样品在水中浸泡72h后，剖开样品的绝缘表面应该是干燥的；铝塑复合带纵包后粘结完全、紧密，缆芯圆整，平整不起空，按照IEC 60840附录G的规定进行铝塑复合带搭接处剥离强度试验，其最小值不小于0.5N/mm；铝塑复合带和聚乙烯护套粘接紧密，电缆外观圆整，表面光洁，颜色均匀，按照IEC 60840附录G的规定进行铝塑复合带与聚乙烯护套料之间剥离强度试验，其最小值不小 于0.5N/mm。
综上所述，本发明创造的纵向径向阻水中压电缆导体和金属屏蔽层均具备纵向阻水特性，加之铝塑复合带作为纵向阻水层，有效降低电缆的击穿故障率，即使在潮湿环境中也能长期安全稳定运行，在产品生命周期内大大节约了铜、铝、聚乙烯等材料的消耗，有力推进电缆行业绿色发展。

Claims (8)

  1. 一种纵向径向阻水中压电力电缆的制造方法，步骤包括：1)制造线芯；2)制造缆芯；3)制造防护层，其特征是
    所述步骤1)包括：
    1.1)制备导体；
    1.2)在导体外依次包裹第一层阻水膨胀带材、半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层；
    所述步骤2)包括：
    2.1)在步骤1)制得线缆外依次包裹第二层阻水膨胀带材和金属屏蔽层；
    所述步骤3)包括：
    3.1)在步骤2)制得线缆外依次包裹第一绕包带层、径向防水层和第一护套层；
    所述步骤1.1)中，导体是由金属单丝与阻水材料紧压绞合构成的圆形纵向阻水导体；
    所述步骤1.2)包括：
    1.2.1)第一层阻水膨胀带材是由一层或者多层半导电阻水带绕包构成，绕包的平均重叠率不小于15％；
    1.2.2)半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层是挤包相应电缆料构成；
    所述步骤2.1)中，第二层阻水膨胀带材是由一层或者多层半导电阻水带绕包构成，绕包的平均重叠率不小于15％；
    所述步骤3.1)中，
    所述第一绕包带层是由绕包带绕包构成，绕包带是双面绝缘阻水带，绕包的平均重叠率不小于15％，最小重叠不小于5mm；双面绝缘阻水带的标称厚度至少是0.35mm；
    所述径向防水层是由铝塑复合带沿缆芯的轴线方向纵包在第一绕包带层外构成，要求包括：
    a、铝塑复合带的厚度是不小于0.25mm，铝塑复合带左右两边的塑料部分热熔粘接起来，重叠部分不小于5mm；
    b、模具要求：沿生产线前进方向，依次设置纵包套管、喇叭膜、稳线模和定径模，最后送入第一护套层的挤塑机头；
    喇叭模出口直径＝线缆直径+(2.0～2.5)mm；稳线模出口直径＝电线缆直径+(1.5～2.0)mm；定径模出口直径＝线缆直径+(1.0～1.5)mm；
    在喇叭模、稳线模和定径模中均采用热电偶对铝塑复合带进行加热；喇叭模、稳线模和定径模的温度依次设定为120℃、140℃和160℃；
    分别在三个模具之前各有一个热电吹风装置，对准铝塑复合带两条边的纵向边缘搭接处的缝隙，对铝塑复合带进行加热软化使其具有黏性，加热温度依次设定为140℃、160℃和160℃；
    最终在定径模的作用下，两条纵向边缘完全、紧密粘接，粘接后铝塑复合带平整，构成管状结构包在第一绕包带层外；
    所述第一护套层是在径向防水层外挤包聚乙烯护套料，工艺要求包括：
    自进料到出料方向，挤塑机的机身各区温度分布为：一区温度范围是170℃～180℃；二区、三区和四区温度范围都是是175℃～185℃；五区和六区温度范围都是180℃～190℃；
    其中：一区为入料段，二区、三区和四区为塑化段，五区、六区为均化段；
    挤塑机的机头单元温度为：机颈的温度范围是185～195℃、机头的温度范围是185～195℃、模口的温度范围是185～195℃；
    护套应采用分段冷却，第一段冷却水槽水温为50～70℃，其后均采用常温水。
  2. 根据权利要求1所述电缆的制造方法，其特征是所述导体的金属单丝是由铜单丝或铝单丝；阻水材料是阻水膨胀纱、阻水膨胀带或阻水膨胀粉。
  3. 根据权利要求1所述电缆的制造方法，其特征是所述步骤1.2.2)中，半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层是三层共挤相应电缆料构成，工艺要求为：
    半导电导体屏蔽层挤塑机温度依次设定为：一区60℃，二区95℃、三区105℃、四区106℃、五区106℃、机颈106℃、机头106℃和模口106℃，温度设定偏差±5℃；
    抗水树型交联聚乙烯绝缘层挤塑机温度依次设定为一区80℃、二区116℃、三区118℃、四区120℃、五区120℃、机颈120℃、机头120℃和1模口20℃，温度设定偏差±5℃；
    半导电绝缘屏蔽层挤塑机温度依次设定为一区60℃、二区95℃、三区105℃、四区112℃、五区112℃、机颈112℃、机头112℃和模口112℃，温度设定偏差±5℃；
    冷却是采用冷水冷却；
    步骤1.2.2)中挤塑剂，一区为入料段，二区和三区为塑化段，四区和五区为均化段。
  4. 根据权利要求1所述的电缆的制造方法，其特征是金属屏蔽层是铜丝屏蔽层；铜丝屏蔽层的外表面由反向绕包的铜丝或铜带扎紧；铜丝屏蔽层的相邻铜丝的平均间隙不大于4mm；
    或者，金属屏蔽层是铜带屏蔽层，铜带屏蔽层是一层或者多层重叠绕包的软铜带构成；绕包的平均搭盖率不小于15％，且最小搭盖率不小于5％，铜带标称厚度不小于0.12mm；
    第一护套层的标称厚度不小于1.4mm。
  5. 根据权利要求1～4任一所述电缆的制造方法，其特征是所述步骤2)还包括：
    步骤2.2)把多根步骤2.1)制得线缆进行绞合，绞合后，各根线缆的金属屏蔽层是相同导通的；
    所述步骤3)还包括：
    步骤3.2)在步骤3.1)制得线缆外依次包裹金属铠装层、第二绕包带层和第二护套层；
    所述步骤3.1)中，第一绕包带层的多根步骤2.1)制得线缆之间填满填充；
    所述步骤3.2)中，金属铠装层是金属丝铠装层或金属带铠装层；所述第二绕包带层的绕包平均重叠率都不小于15％，最小重叠不小于5mm；
    所述第二护套层是在第二绕包带层外挤包聚乙烯护套料，工艺要求包括：
    自进料到出料方向，挤塑机的机身各区温度分布为：一区温度范围是170℃～180℃；二区、三区和四区温度范围都是175℃～185℃；五区和六区温度范围都是180℃～190℃，其中：一区为入料段，二区、三区、四区为塑化段，五区、六区为均化段；
    挤塑机的机头单元温度为：机颈温度范围是185～195℃、机头温度范围是185～195℃、模口温度范围是185～195℃；
    护套应采用分段冷却，第一段冷却水槽水温为50～70℃，其后段均采用常温水冷却。
  6. 根据权利要求5所述电缆的制造方法，其特征是所述金属铠装层是金属带绕包铠装层，金属带是镀锌钢带或不锈钢带；
    金属带的标称厚度为0.5mm或0.8mm，绕包间隙不大于金属带宽度的50％，且内层金属带的间隙被外层金属带的靠近中间的部位所覆盖；
    或者，所述金属铠装层是金属丝绕包铠装层，金属丝是镀锌钢丝或不锈钢丝；
    金属丝的标称直径为1.25mm、1.6mm、2.0mm、2.5mm或3.15mm；金属丝铠装层的铠装总间隙不大于一根金属丝的直径，金属丝绕包的节径比是12～16倍；
    第二绕包带层的绕包带是标称厚度为0.2mm或0.3mm的无纺布。
    第二护套层的标称厚度不小于1.8mm。
  7. 一种权利要求1所述方法制得的单芯纵向径向阻水中压电力电缆，其特征是包括缆芯，以及在缆芯外依次包裹的第一绕包带层、径向防水层和护套层；
    所述缆芯的结构为：导体依次包裹第一层阻水膨胀带材、半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层和半导电绝缘屏蔽层构成线芯；在一根线芯外包裹第二层阻水膨胀带材和金属屏蔽层构成缆芯；
    所述导体是由金属单丝与阻水材料紧压绞合构成的圆形纵向阻水导体；
    所述第一层阻水膨胀带材和第二层阻水膨胀带材都是由一层或者多层半导电阻水带绕包构成，绕包的平均重叠率不小于15％；
    所述第一绕包带层是由绕包带绕包构成，绕包带是双面绝缘阻水带，绕包的平均重叠率不小于15％，最小重叠不小于5mm；双面绝缘阻水带的标称厚度至少是0.35mm；
    所述径向防水层是由铝塑复合带沿缆芯的轴线方向纵包在第一绕包带层外；铝塑复合带的厚度是不小于0.25mm，铝塑复合带左右两边的塑料部分热熔粘接起来，重叠部分不小于5mm；
    护套层是在径向防水层外挤包聚乙烯护套料构成。
  8. 一种权利要求5方法制得的多芯纵向径向阻水中压电力电缆，其特征是包括缆芯，以及在缆芯外依次包裹的第一绕包带层、径向防水层、内护套层、金属铠装层、第二绕包带层和外护套层；
    所述缆芯是由多根线芯绞合构成，任一线芯的结构为：导体依次包裹第一层阻水膨胀带材、半导电导体屏蔽层、抗水树型交联聚乙烯绝缘层、半导电绝缘屏蔽层、第二层阻水膨胀带材和金属屏蔽层；第一绕包带层内的各个线芯之间填满填充；
    所述导体是由金属单丝与阻水材料紧压绞合构成的圆形纵向阻水导体；
    所述第一层阻水膨胀带材和第二层阻水膨胀带材都是由一层或者多层半导电阻水带绕包构成，绕包的平均重叠率不小于15％；
    所述第一绕包带层是由绕包带绕包构成，绕包带是双面绝缘阻水带，绕包的平均重叠率不小于15％，最小重叠不小于5mm；双面绝缘阻水带的标称厚度至少是0.35mm；
    所述径向防水层是由铝塑复合带沿缆芯的轴线方向纵包在第一绕包带层外；铝塑复合带的厚度是不小于0.25mm，铝塑复合带左右两边的塑料部分热熔粘接起来，重叠部分不小于5mm；
    所述内护套层是在径向防水层外挤包聚乙烯护套料构成；
    所述金属铠装层是金属丝铠装层或金属带铠装层；
    所述第二绕包带层的绕包平均重叠率都不小于15％，最小重叠不小于5mm；
    所述外护套层是在第二绕包带层外挤包聚氯乙烯护套料、聚乙烯护套料或低烟无卤阻燃料构成。
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