CN101908391B - Carbon fiber-resin composite core for overhead cable - Google Patents
Carbon fiber-resin composite core for overhead cable Download PDFInfo
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- CN101908391B CN101908391B CN2010102207484A CN201010220748A CN101908391B CN 101908391 B CN101908391 B CN 101908391B CN 2010102207484 A CN2010102207484 A CN 2010102207484A CN 201010220748 A CN201010220748 A CN 201010220748A CN 101908391 B CN101908391 B CN 101908391B
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Abstract
The invention relates to a carbon fiber-resin composite core for overhead cables, which consists of a carbon fiber-resin composite core layer and a protective layer wound on the core layer, wherein the protective layer is a fibrofelt and/or fiber fabric-reinforced resin material layer. Compared with the prior art, the carbon fiber-resin composite core for the overhead cables has the advantages of reducing the unit length weight of a product and improving flattening resistance.
Description
Technical field
The present invention relates to a kind of fibre reinforced composites, relate more specifically to the core of aerial cable.
Background technology
Over past ten years, along with the development of aerial cable technology, original steel core is replaced by the higher non-metallic fibers composite core of intensity, and this composite core reinforced cable (ACCC) has reduced cable weight and degree of sag significantly than the steel core cable.The nonmetal fortifying fibre that becomes known for aerial cable has that carbon fiber, Kev draw, basalt, glass fiber, aromatic polyamide, liquid crystal fiber, high-performance polyethylene etc.Wherein, because carbon fiber has high hot strength and low thermal coefficient of expansion, in the aerial cable core, adopted more and more.
Chinese patent ZL03809284.0 has disclosed a kind of composite core that is used for cable, and this composite core comprises inner core and outer core.Wherein inner core comprises many carbon fibers vertical and continuous, that have the higher elasticity modulus, outer core comprise many vertical and continuous, have a glass fiber than low elastic modulus.This inside and outside layer fiber all is wrapped in the thermosetting resin.This composite core can reach hot strength, thermal coefficient of expansion and the heat-resisting quantity that suits the requirements, and therefore can overcome the heavier and more serious problem of sag of weight of steel core cable well.
This patent is thought, utilizes the carbon fiber composite epoxy resin less feasible as the composite core material merely, because the flexibility of carbon tube/epoxy resin core is very little, is difficult for the packing of reeling.For this reason, this patent is the skin of glass fiber-resin bed design at material cores, and from core the sectional area of carbon fiber and glass fiber, the consumption of glass fiber is not less than the consumption of carbon fiber.Simultaneously, be that carbon fiber layer and aluminium conductor are separated with the glass fiber design in outer field another purpose, contact with aluminium conductor to prevent carbon fiber with electrical conductance, cause the potential difference corrosion, thus reduction of service life.
But also there is defective in the compound design of this two fibrids, complex process, and quality control requirement is higher, and the transverse strength of goods is low.At first, in order to produce the core of the outer carbon coated fiber of glass fiber internal layer, on manufacturing process, need comparatively complicated operations.Aborning, need many glass fiber bundles are passed the bullport of guided plate (be provided with and have the bullport of subscribing pattern), be evenly distributed on the periphery of carbon fiber bundle, in the drawing process of wire harness, need prevent the dish knot between the wire harness.Usually the length of fiber material is about 5000m, therefore, whenever at a distance from about 5000m, just need repeat the operation of once two fibrids being put on the shelf, and the location of entrying moves towards more numerous and diverse.Secondly, two fibrids are portrait orientation, and the transverse strength of goods only depends on the intensity of resin, and transverse strength is lower.
Summary of the invention
The present invention proposes a kind of improved carbon fiber enhancement resin base composite material cable core, to overcome the existing problem that manufacturing process is complicated, transverse strength is low by the compound enhancing cable core of two fibrids.
Another object of the present invention is further to reduce the weight of existing cable core, to reduce the sag degree of cable core.
The carbon fiber-resin composite core that the present invention is used for aerial cable is to be made up of carbon fiber-resin composite core layer and protective layer around said sandwich layer, and wherein, this protective layer is the resin material layer that is strengthened by fibrofelt and/or fabric.
In embodiment of the present invention, this fibrofelt is thermoplastic resin fibre's felt or glass mat.
In another kind of embodiment of the present invention, this protective layer is to strengthen resin by glass fabric and/or basalt fibre fabric to constitute.
In a kind of embodiment of the present invention, this protective layer comprises said fibrofelt of multilayer and fabric, is that the form with the loop bonding felt is combined with each other between these layers.
Aerial cable of the present invention has reduced the unit weight of product with carbon fiber-resin composite core compared to aforementioned prior art, and has improved anti-flattening.
Description of drawings
Fig. 1 is the sketch map that is used to produce the production equipment of composite core of the present invention.
Embodiment
Aerial cable of the present invention comprises the sandwich layer by carbon fiber and resin compounded with the carbon fiber resin composite material core, and the external protection that is made up of fibrofelt and/or fabric.
The K number that is used for carbon fiber of the present invention can be between 1K～80K, wherein preferably between 6K～24K.Cause cable core too rigidity, difficult defective of reeling for fear of simple use carbon fiber, need the consumption of carbon fiber in the control cable core.Under the prerequisite that satisfies the tensile strength needs, should not use too much carbon fiber.Carbon fiber volume content is no more than 70%, preferably is no more than 65%.
In exemplary embodiment of the present invention, the carbon fiber that uses is T700SC-12K.Can confirm its consumption in cable core according to the difference of selected carbon fiber performance parameter (for example hot strength, stretch modulus).Another factor that when confirming the carbon fiber consumption, need consider is the kind of resin, and this is owing to can cause different performance parameters with a kind of carbon fiber with the combination of different resins.In general; Because the present invention mainly makes reinforcing material with carbon fiber; For reaching the target capabilities of cable core, for example, be not less than the hot strength of 3500MPa; Be not less than the stretch modulus of 225MPa, the consumption of required carbon fiber only needs the consumption of carbon fiber when using composite fibre among the patent ZL03809284.0.The a spot of increase of carbon fiber can improve the hot strength and the stretch modulus of cable core significantly, and coiling property that can the appreciable impact composite core.Simultaneously, owing to do not re-use a large amount of glass fibers, help reducing the coefficient of linear expansion of core.So a small amount of increase of carbon fiber is used the heat-resisting sag that has just in time improved the linear expansivity of plug and reduced plug with the decrement of a large amount of glass fibers.
The present invention can adopt any suitable resin.In addition, in various execution modes, the design resin is so that preparation easily.According to the present invention,, can optimize the viscosity of various resins for high response and line speed faster.In one embodiment, can adopt the epoxy anhydride system.The importance of optimizing resin system for the required character of core and preparation is to select best catalyst combination.For example, optimize catalyst (or promoter), the minimum side reaction that causes crackle to produce takes place in curing with the resin Composition that produces maximum at short notice simultaneously.In addition, expect that also catalyst is inactive in order to increase storage period at low temperatures, and need guarantee that the pultrusion time the fastest in the preparation process at high temperature is very active.
In embodiments, especially for high temperature curing process design vinyl ester resin.Another instance is a liquid epoxies, and other instance comprises polyetheramides, BMI (bismalimide), various acid anhydrides, perhaps acid imide.In addition, can select curing agent according to final composite material core component required character and processing method.For example, curing agent can be aliphatic polyamine, polyamide and modified product thereof.Other suitable resin can comprise thermosetting resin, thermoplastic resin or thermoplastic modified resins, toughened resin (toughened resin), the resin of elastomeric modification, multifunctional resin, cyanate or poly-cyanate ester resin.Some thermosetting and thermoplastic resin can include, but not limited to epoxy, high temperature polymer (polyimides), nylon, fluoropolymer, polyethylene (polyethelene), vinyl esters etc.One of ordinary skill in the art will recognize that in the present invention and can use other resin.
According to calculated cable application, select the resin that suits according to required cable property, so that composite core has long term durability in hot operation.Can also select suitable resin according to the formation method of composite core,, thereby increase processing speed, and be implemented in the ratio of fiber and resin suitable in the final composite core so that friction is minimum in the processing procedure.According to the present invention, the viscosity of resin can be about 50～10000cPs, is preferably about 500～3000cPs, more preferably about 800-1800cPs.
Composite core of the present invention comprises the resin with good mechanical property and chemical-resistant.These resins can still can play a role under environment in long term exposure at least in 40 years that use.More preferably, composite core of the present invention can be included in use at least about the resin that under long term exposure, has good mechanical property and chemical-resistant, resistance to water and anti-UV property in 80 years.And composite core of the present invention comprises such resin, and it can be worked under the temperature of 45～240 ℃ (preferential treatment is at 45～200 ℃) anywhere, and under temperature extremes, has the minimum characteristic of structural behaviour decline.
According to the present invention, for character and the preparation process of optimizing composite core, resin can comprise various ingredients.In various embodiments, resin comprises one or more curing agent/promoter, in solidification process, to give a hand.The promoter of selecting is depended on mold temperature in resin and the preparation process.And in order to improve line speed and surface quality, resin can comprise that surfactant is to help to reduce surface tension.Resin can also comprise clay or other filler.These compositions have increased volume for resin, and play a part to reduce cost, and keep the physical property of resin simultaneously.Can also add extra additive, for example, make the additive of anti-UV of the anti-UV of resin, and color additive (coloring additive).
Usually, the elongation property of resin system should surpass the elongation property of the carbon fiber that adopts.For example, the embodiment of epoxy systems can comprise the low viscosity polyfunctional epoxy resin that utilizes anhydride hardener and imidazoles promoter.The instance of such epoxy systems can be
MY721/ curing agent 99-023/ diphenylguanidine Y070 heat curing epoxy matrix system of being made by HuntsmanInc.Said resin has N, N, N ', N '-four glycidyl group-4, the chemical name of 4 '-methylene dianiline (MDA) (methylenebisbenzenamine).Wherein, curing agent is 1H-imidazoles, l-methyl isophthalic acid-methylimidazole.Use especially and this exemplary resin epoxy systems of modification can have following character: about 3.0～5.0% tensile elongation for ACCC; The flexural strength of about 16.5～19.5Ksi; The hot strength of about 6.0～7.0Ksi; The stretch modulus of about 450,500Ksi; And about 4.5～6.0% flexural elongation.Another embodiment of epoxy-resin systems can be multi-functional epoxy and alicyclic-amine mixed hardening agent.The instance of the epoxy systems of the type can be the JEFFCO1401-16/4101-17 epoxy systems of being made by JEFFCO ProductsInc. that is used to flood.This exemplary resin epoxy systems can have following character: the Shore D hardness of about 88D; 9.7Ksi ultimate tensile strength; About 4.5～5.0% percentage elongation under hot strength; About 7.5～8.5% ultimate elongation; The flexural strength of about 15.25Ksi; And the compressive ultimate strength of about 14.5Ksi.These embodiments of epoxy-resin systems are exemplary, are not to limit the invention to these concrete epoxy-resin systems.One of ordinary skill in the art will recognize that other epoxy systems also can produce the composite core in the scope of the invention.
Composite core of the present invention can comprise such resin, and it is enough tough and be able to take stranded operation, and does not make composite material produce crack or fracture.Composite core of the present invention can comprise that pure resin fracture toughness (net resin fracture toughness) is at least about the resin of 0.96MPam1/2.
Composite core of the present invention can comprise the resin with low thermal coefficient of expansion.Low thermal coefficient of expansion reduces the sag of resulting cable.Resin of the present invention can have less than about 4.2 * 10
-5/ ℃ with maybe be less than 1.5 * 10
-5/ ℃ thermal coefficient of expansion.Composite core of the present invention can comprise that percentage elongation is greater than about 3% or more preferably from about 4.5% resin.
The skin of cable core of the present invention is provided with layer protective layer, directly contacts with aluminum conductor to isolate the carbon fiber sandwich layer, prevents to produce galvano-cautery.This protective layer be the fibrofelt of thickness between 0.02～1.5mm with (or) resin material layer that strengthens of fabric.In process of production, through the peripheral resin more than needed of sandwich layer, fibrofelt or fabric are combined closely on sandwich layer via extruding.In the present invention, fibrofelt is meant its fiber equally distributed nonwoven fabrics on all directions.And fabric is that fiber is in the crisscross woven cloth of orthogonal basically both direction.This nonwoven fabrics or woven cloth can also provide the anti-flattening of cable core in radial direction except avoiding carbon fiber and aluminium directly to contact the generation galvano-cautery.
Anti-flattening is meant plug radial force deformation ability, anti-extruding, jolt capacity at aluminum steel in the stranded or plug transportation installation process.Usually weigh to flatten intensity, but press the GB/T23171 quantitative assay
Be all the situation of longitudinal extension for fiber in the prior art; Fiber can not provide cable core mechanical strength radially; This cable core have when receiving radial compression in the stranded or plug transportation installation process at aluminum steel distortion, cracking maybe, plug vertically on cut or breach are arranged, in case curved transitions or receive external force collision; Plug is very easy in the machine direction cracking, causes the plug damage to use.And the present invention is different from this, nonwoven fabrics or woven form, thickness can provide cable core in tension radially, anti-extrusion performance at the fibrofelt of above-mentioned scope, this can give and produce or use and bring benefit.
Be used for normally thermoplastic resin fibre's felt of fibrofelt of the present invention.Be the application purpose of cable core, the fusing point of thermoplastic resin should be not less than 220 ℃, preferably is not less than 270 ℃.In addition, selecteed thermoplastic resin also should possess higher weatherability.The thermoplastic resin that is suitable for fibrofelt includes but not limited to polyester (PET), polyethersulfone resin (PES), nylon (PA), polyimide resin (PIM), polyether-ether-ketone (PEEK), polyphenylene sulfide (PPS).
Above-mentioned fibrofelt can obtain from market buying, and for example model is the surperficial felt of polyester (PET) of NLC10/350N, unit are heavily be 40 ± 5 grams/square metre, belong to the polyethylene terephthalate copolymer modified fibre, longitudinal tensile strength 95N/5cm, transverse tensile strength 26N/5cm.
Also can adopt glass mat, the MFS-50. glass mat sold of the rich white composite material in Guangzhou Co., Ltd for example, thickness is 0.05mm; Weight per unit area be 50 the gram/square metre; Gel content is less than 6%, and longitudinal tensile strength is not less than 30N/5cm, and water content is less than 0.2%.
As a kind of optimal way, can form protective layer with fabric.Fiber in the fabric is not only continuous (long size), and on two or more directions, interweaves.Than nonwoven fabrics, it provides higher radial mechanical performance (longitudinal fiber in woven cloth extends along the cable core length direction, and radial fiber is along under the situation of the circumferential extension of cable core).
Can as required above-mentioned fibrofelt be designed to one or more layers.Under the situation of multilayer, these layers can adopt material different, and for example one deck is used basalt fibre with thermoplastic resin fibre, another layer with glass fiber, another layer.These layers must be used various structure, and for example wherein one deck is the nonwoven fabrics form, and another layer is the woven cloth form.This sandwich construction is desirable in some cases.Adopting this loop bonding felt is the radial strength that has improved core on the one hand, and promptly anti-flattening on the other hand, has been improved the coiling property of core.This structure is general use at external diameter big slightly (in the moulding of the core of D >=8mm).Can be combined with each other with the form of loop bonding felt between these layers, in mould, be combined in the carbon fiber core laminar surface securely then through the curing of sandwich layer resin.
In the present invention, between 0.02～1.5mm, if thickness surpasses 1.5mm, then protective layer occupies too much weight to the thickness of protective layer, can be unfavorable to the weight saving of cable core usually; If thickness is lower than 0.02mm, then because the fiber in the protective layer very little, can not provide enough anti-flattenings.The thickness of protective layer can be done some variation according to the difference of fiber material.For example, for thermoplastic resin fibre's felt, the thickness of protective layer can be between 0.02-0.5mm, and for glass mat, thickness can be between 0.02-1.2mm, preferably between 0.4-0.8mm.In addition, for the situation that adopts fabric fibre,, can thickness be reduced because it has higher intensity.Under the situation that adopts sandwich construction, the gross thickness of protective layer can be between 0.3-1.5mm.
Adopt fibrofelt of the present invention and/or fabric can obtain such advantage: at first; Than resin molding protective layer of the prior art; The hot strength that it has improved vertical and horizontal has improved the anti-collapse performance of cable core, makes cable core in transportation, installation process, can not ftracture; Secondly, fibrofelt and/or fiber fabric layer have replaced glass fiber-resin bed of the prior art, on thickness, reduce greatly, have therefore significantly reduced the total weight of cable core; Once more, simplified production technology.In order to produce cable core of the present invention; Directly draw carbon fiber from creel; Get into steeping vat, boundling becomes single circular cross-section and extrudes resin more than needed then, outside sandwich layer, coats fibrofelt and/or fabric, get into to solidify the die cavity setting; Than patent ZL03809284.0, the present invention has improved production efficiency.
Embodiment
Raw material specification:
Carbon fiber: Torayca T700SC-12K, hot strength 4900MPa, stretch modulus 235GPa, strain 2.1%, filament diameter 7 μ;
Epoxy-resin systems: 25 ℃ of viscosity 1200-2000cP, 25 ℃ of density 1.2g/cm
3
Glass mat: MFS-50;
Glass fiber loop bonding felt: GF/960-50-35.
Fig. 1 is the production equipment sketch map that is used to produce composite core of the present invention.As shown in Figure 1, carbon fiber with constant tension force debatching, passes guide plate 2 from the creel 1 that has tension adjusting device according to the order of sequence; Pass through preheating cabinet 3 abreast; In preheating cabinet, get rid of moisture, and the sizing agent of thermoplastic carbon fiber surface, the resin effect of impregnation may improved.And then, get into glue groove 4 through guide plate 2 '.After fully soaking into, get into preforming tool 5.In this stage, extrude unnecessary resin, and converge with fibrofelt; Coat fully, draw to mould 6, be heating and curing through three districts; Plug moves out of mould with the speed of 0.35m/min, gets into back curing oven 7 at last, carries out online back and solidifies; Through haulage gear 8, pull out plug then, by wrap-up 9 even close winds on Scroll.
Adopt glass mat and glass fiber loop bonding felt to make sample 1 and sample 2 respectively.
In sample 1, glass mat adopts MFS-50, has the hot strength that is not less than 30N/5cm, and the plug internal layer is the carbon fiber and the epoxy resin composite bed of diameter 8.08, the gross area 51.25mm of carbon fiber layer
2, skin is glass mat/epoxy resin composite bed, the area of glass fiber carpet veneer is 0.89mm
2, diameter of mandrel is 8.15mm, and the fiber volume fraction of internal layer carbon fiber is 68%, and the fiber volume fraction of outer glass felt is 65%.
In sample 2, glass fiber loop bonding felt adopts GF/960-50-35, and (glass fiber of unit are is 960g/m
2, glass mat is 50g/m
2, width is 35mm), have the hot strength of 2200Mpa, the plug internal layer is the carbon fiber/epoxy resin composite bed of diameter 6.8mm, the gross area 36.93mm of carbon fiber layer
2, skin is glass fiber loop bonding felt/epoxy resin composite bed, the area of glass fiber seam bridal veil carpet veneer is 15.84mm
2, diameter of mandrel is 8.13mm, and the fiber volume fraction of internal layer carbon fiber is 68%, and the fiber volume fraction of glass outer fiber loop bonding felt is 65%.
Comparative Examples
According to the disclosure of aforementioned patent, prepare a reference substance cable core reference substance, the resin of its carbon fiber layer is identical with the embodiment of the invention with the carbon fiber materials, and glass fiber adopts Vetrotex rove R099-69-86 (900 yards), has the stretch modulus of 77GPa.The cable core internal layer is the carbon fiber/epoxy resin composite bed of the about 6mm of diameter, the about 28.26mm of the gross area of carbon fiber
2, skin is glass fiber/epoxy resin composite bed of diameter 8.13mm, the wherein about 23.63mm of the gross area of glass fiber
2Carbon fiber in the internal layer/weight resin ratio is 70/30, and the fiber/resin weight ratio is 75/25 in the outer glass fibrage.
The various parameters of each sample and reference substance have been listed in the table 1.
Table 1
| Parameter | Reference substance 1 | Sample 1 | Sample 2 |
| Weight (g/m) | 96 | 83.5 | 91 |
| Cable core diameter (mm) | 8.13 | 8.15 | 8.15 |
| Sandwich layer diameter (mm) | 6 | 8.08 | 6.8 |
| Protective layer thickness (mm) | - | 0.035 | 0.675 |
| The fiberglass/resin layer thickness | 1.06 | - | - |
| Curl and test (55D) | Qualified | Qualified | Qualified |
| Modulus of elasticity (GPa) | 118 | 118 | 116 |
| Hot strength (MPa) | 2200 | 2500 | 2400 |
| Anti-collapse test (kN) | 26.5 | 32 | 36 |
Can find out that from The above results product according to the present invention is being superior to reference substance aspect the anti-collapse performance, aspect weight, has reduced by 5～10% than reference substance.And performance parameter in other respects and reference substance have quite perhaps reached instructions for use.
Although the present invention has combined accompanying drawing and preferred embodiment to be illustrated, obviously, for a person skilled in the art, under the prerequisite that does not deviate from the spirit and scope of the present invention, can make various changes and variation to the present invention.Therefore, various change of the present invention, the content that changes by appending claims and equivalent thereof contain.
Claims (5)
1. carbon fiber-resin composite core that is used for aerial cable; It is characterized in that, its by the carbon fiber-resin composite core layer with constitute around the protective layer of said sandwich layer, wherein; Said protective layer is the resin material layer that fibrofelt and fabric strengthen; The K number of said carbon fiber is between 1K-80K, and staggered being combined with each other of said fibrofelt and fabric forms the loop bonding felt, and said loop bonding felt forms said protective layer through resin solidification in said core layer surface.
2. composite core according to claim 1, wherein, said fibrofelt is thermoplastic resin fibre's felt.
3. composite core according to claim 1, wherein, said fibrofelt is a glass mat.
4. according to each described composite core in the claim 1 to 3, wherein, the thickness of said protective layer is between 0.02～1.5mm.
5. according to each described composite core in the claim 1 to 3, wherein, the fiber volume fraction of said cable core is between 50%～74%.
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| US9443635B2 (en) | 2011-04-12 | 2016-09-13 | Southwire Company, Llc | Electrical transmission cables with composite cores |
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| CN107742542B (en) * | 2011-04-12 | 2019-10-01 | 南方电线有限责任公司 | Power transmission cable with composite core |
| CN106205904B (en) * | 2016-06-20 | 2017-06-27 | 河南省亚安绝缘材料厂有限公司 | A kind of environmentally friendly composite insulating material |
| CN106782850A (en) * | 2017-03-07 | 2017-05-31 | 河北硅谷化工有限公司 | A kind of aerial condutor carbon fiber composite core bar and its processing method |
| CN109378669A (en) * | 2018-12-10 | 2019-02-22 | 河北硅谷化工有限公司 | A kind of electric railway novel carbon fiber composite core contact line and its manufacture craft |
| WO2024007179A1 (en) * | 2022-07-06 | 2024-01-11 | 远东电缆有限公司 | Thermoplastic carbon fiber composite material, and preparation method therefor and use thereof |
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| CN2847470Y (en) * | 2005-05-26 | 2006-12-13 | 江苏远东集团有限公司 | Carbon fiber composite core aluminum stranded conductor and insulation cable |
| CN201237921Y (en) * | 2008-08-07 | 2009-05-13 | 大庆石油新科庆联防腐有限公司 | Composite material core for feeder cable |
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| US9443635B2 (en) | 2011-04-12 | 2016-09-13 | Southwire Company, Llc | Electrical transmission cables with composite cores |
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