CN113871059B - Preparation process of carbon fiber composite aluminum alloy overhead cable - Google Patents
Preparation process of carbon fiber composite aluminum alloy overhead cable Download PDFInfo
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- CN113871059B CN113871059B CN202111126020.XA CN202111126020A CN113871059B CN 113871059 B CN113871059 B CN 113871059B CN 202111126020 A CN202111126020 A CN 202111126020A CN 113871059 B CN113871059 B CN 113871059B
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- 229920000049 Carbon (fiber) Polymers 0.000 title claims abstract description 139
- 239000004917 carbon fiber Substances 0.000 title claims abstract description 139
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 title claims abstract description 106
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 67
- 239000002131 composite material Substances 0.000 title claims abstract description 51
- 238000002360 preparation method Methods 0.000 title claims abstract description 10
- 239000011162 core material Substances 0.000 claims abstract description 48
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 43
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 43
- 238000005253 cladding Methods 0.000 claims abstract description 39
- 239000011247 coating layer Substances 0.000 claims abstract description 25
- 239000010410 layer Substances 0.000 claims abstract description 9
- 229910052751 metal Inorganic materials 0.000 claims description 27
- 239000002184 metal Substances 0.000 claims description 27
- 238000000034 method Methods 0.000 claims description 19
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 17
- 229910052749 magnesium Inorganic materials 0.000 claims description 17
- 239000011777 magnesium Substances 0.000 claims description 17
- 238000004519 manufacturing process Methods 0.000 claims description 16
- 229920001721 polyimide Polymers 0.000 claims description 15
- 239000000835 fiber Substances 0.000 claims description 14
- 239000004642 Polyimide Substances 0.000 claims description 13
- 238000001125 extrusion Methods 0.000 claims description 12
- 238000010924 continuous production Methods 0.000 claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 10
- 238000005097 cold rolling Methods 0.000 claims description 8
- 238000007789 sealing Methods 0.000 claims description 8
- 238000003466 welding Methods 0.000 claims description 8
- 230000008018 melting Effects 0.000 claims description 7
- 238000002844 melting Methods 0.000 claims description 7
- 238000005245 sintering Methods 0.000 claims description 7
- 239000011248 coating agent Substances 0.000 claims description 6
- 238000000576 coating method Methods 0.000 claims description 6
- 238000005096 rolling process Methods 0.000 claims description 6
- 239000002994 raw material Substances 0.000 claims description 5
- 238000011049 filling Methods 0.000 claims description 4
- 239000011521 glass Substances 0.000 claims description 4
- 239000002861 polymer material Substances 0.000 claims description 4
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 3
- 239000012298 atmosphere Substances 0.000 claims description 3
- 238000001035 drying Methods 0.000 claims description 3
- 229910052748 manganese Inorganic materials 0.000 claims description 3
- 239000011572 manganese Substances 0.000 claims description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 2
- 238000009835 boiling Methods 0.000 claims description 2
- 239000000919 ceramic Substances 0.000 claims description 2
- 229910052802 copper Inorganic materials 0.000 claims description 2
- 239000010949 copper Substances 0.000 claims description 2
- 239000000463 material Substances 0.000 claims description 2
- 239000002120 nanofilm Substances 0.000 claims description 2
- 238000000643 oven drying Methods 0.000 claims description 2
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- 238000003825 pressing Methods 0.000 claims description 2
- 238000007711 solidification Methods 0.000 claims description 2
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- 239000002904 solvent Substances 0.000 claims description 2
- 229920003002 synthetic resin Polymers 0.000 claims description 2
- 238000007740 vapor deposition Methods 0.000 claims description 2
- 238000004804 winding Methods 0.000 claims description 2
- 239000007888 film coating Substances 0.000 claims 1
- 238000009501 film coating Methods 0.000 claims 1
- 239000004020 conductor Substances 0.000 abstract description 7
- 229910000831 Steel Inorganic materials 0.000 abstract description 5
- 239000010959 steel Substances 0.000 abstract description 5
- 239000000243 solution Substances 0.000 description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 230000005540 biological transmission Effects 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 239000012300 argon atmosphere Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical group [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000007542 hardness measurement Methods 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 2
- 238000004321 preservation Methods 0.000 description 2
- 238000005275 alloying Methods 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 239000008367 deionised water Substances 0.000 description 1
- 229910021641 deionized water Inorganic materials 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000006056 electrooxidation reaction Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
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- 239000007769 metal material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
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- 230000003014 reinforcing effect Effects 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
- H01B5/08—Several wires or the like stranded in the form of a rope
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/14—Metallic material, boron or silicon
- C23C14/18—Metallic material, boron or silicon on other inorganic substrates
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/24—Vacuum evaporation
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/04—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of carbon-silicon compounds, carbon or silicon
-
- 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
-
- 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
- H01B13/0036—Details
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
- Y02A30/14—Extreme weather resilient electric power supply systems, e.g. strengthening power lines or underground power cables
Abstract
The invention discloses a preparation process of a carbon fiber composite aluminum alloy overhead cable, wherein the cable adopts a shell-core structure of an aluminum alloy outer cladding and a core material, the core material consists of a plurality of carbon fiber composite core materials with modified cladding layers coated on the surfaces, each carbon fiber composite core material takes a plurality of carbon fiber bundles as a main body, and the modified cladding layers are coated outside the carbon fiber bundles; the carbon fiber bundles account for 10-80% of the cross section area of the carbon fiber composite core material, and the porosity of the carbon fiber composite core material is 3-15%; the tensile strength of the whole cable exceeds 300MPa, and the tensile modulus exceeds 200GPa. According to the invention, a novel carbon fiber reinforced aluminum cable shell core structure is designed, high-strength and high-modulus carbon fibers are used as cores, aluminum alloy is used as a shell, and a modified coating layer is designed on the outer surface of the carbon fibers. Compared with a steel cable reinforced overhead cable, the lightweight cable is realized, the cable loss is lower, and the elastic modulus, the tensile strength and the flexibility of the cable are obviously improved, so that the durability and the practicability of the conductor cable are greatly improved.
Description
Technical Field
The invention relates to the technical field of power transmission cable manufacturing, in particular to a preparation process of a carbon fiber composite aluminum alloy overhead cable.
Background
Overhead power cables are very important as power transmission carriers in power transmission lines. The metal aluminum is used as a light metal material, has good conductivity and is the main stream of overhead stranded wires. The strength of the metal aluminum is obviously improved in the alloying process, but the conductivity is obviously reduced. In order to ensure the electrical conductivity of the cable, the overhead cable conductor currently used is generally made of aluminum with higher purity. Limited by the strength of pure aluminum itself, the cables employed at this stage typically use high strength steel wires as the load bearing cores, which are even heavier than the cable conductors themselves. As a substitute for high-strength steel wires, carbon fiber composite cables (ACCC) are becoming a new development direction, and particularly carbon fibers have no magnetic loss of steel wires and have greater advantages in long-distance power transmission. The ACCC has complex production process and high raw material cost, and particularly, the price of the used resin is similar to that of the carbon fiber. Firstly, the carbon fiber bundles are required to be bonded by adopting heat-resistant high-strength epoxy resin to form a unidirectional silk composite material, and the surface of the unidirectional silk composite material is coated with a glass fiber insulating layer to remove the risk of electrochemical corrosion. Therefore, the ACCC has the defects of higher cost, higher price of a used connector, higher construction difficulty and the like at present, and therefore, the ACCC cannot become the mainstream.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides the preparation process of the carbon fiber composite aluminum alloy overhead cable which has the advantages of light weight, high modulus, high strength, corrosion resistance, low electric loss and easy construction.
In order to solve the technical problems, the invention adopts the following technical scheme: the utility model provides a carbon fiber composite aluminum alloy overhead cable, is including aluminum alloy surrounding layer and core, and aluminum alloy surrounding layer cladding forms shell core structure, its characterized in that outside the core: the core material consists of a plurality of carbon fiber composite core materials with modified coating layers coated on the surfaces, each carbon fiber composite core material takes a plurality of carbon fiber bundles as a main body, and the modified coating layers are coated outside the carbon fibers; the carbon fiber bundles account for 10-80% of the cross section area of the carbon fiber composite core material, and the porosity of the carbon fiber composite core material is 3-15%; the tensile strength of the whole cable exceeds 300MPa, and the tensile modulus exceeds 200GPa.
Preferably, the aluminum component of the aluminum alloy outer cladding is not less than 98%, other components can effectively reduce the corrosion of the aluminum alloy in a high-humidity and corrosive air environment, and manganese and magnesium are added to form the aluminum alloy, more preferably, the manganese content is 0.4-2%, and the balance is magnesium; the outer diameter of the aluminum alloy cladding is 3-15 mm, and the thickness is 0.3-5 mm.
Preferably, the raw material form for manufacturing the aluminum alloy outer cladding is a strip with the thickness of 0.2-4.5 mm and the width of the strip is 1.3-2 times of the circumference of a cable to be produced, so that the aluminum alloy strip can completely cover the carbon fiber composite core material.
Preferably, the modified coating layer is made of metal, ceramic, glass or heat-resistant high polymer material and the like, and the thickness of the modified coating layer is 10-500 nm; the modified coating layer becomes a bonding material of the carbon fiber in the subsequent process, but only partial bonding is performed, gaps remain in the carbon fiber bundles, and the porosity in the carbon fiber composite core material is 5-10%, so that the flexibility of the cable is increased, the tensile strength of the whole cable exceeds 1500MPa, and the tensile modulus exceeds 250GPa.
Preferably, the modified coating layer is made of magnesium, aluminum or copper and other metals, and the thickness is 30-150 nm.
The carbon fiber can be any one, and can meet the conditions that the deviation of tensile strength and modulus is less than 3% in the same batch, such as M35JB, M40JB, T300, T700 and T800 of Torile, the tensile strength is more than 3000MPa, the tensile modulus is more than 220GPa, the preferable tensile strength is more than 4000MPa, and the tensile modulus is more than 300GPa. The carbon fibers are in a bundle shape, and can be 3K, 6K, 9K, 12K, 24K and the like, or can be used in a multi-bundle and stranded manner, so that the required wire harness is realized.
The preparation process based on the carbon fiber composite aluminum alloy overhead cable is characterized by comprising the following steps of: adopting a continuous production line with the linear speed of 0.1-5 m/s, respectively unreeling the aluminum belt and the carbon fiber, carrying out the following steps,
s1, pressing an aluminum belt for forming an aluminum alloy outer cladding into a U-shaped structure through a cold press, and extruding a disc with the width slightly smaller than that of an opening of the U-shaped structure towards the bottom to realize compact filling;
s2, introducing the carbon fiber bundles which are subjected to coating treatment and provided with the modified coating layer into a U-shaped aluminum belt;
s3, deforming the U-shaped aluminum strip into a circular tube shape or a hexagonal tube shape in an extrusion mode to form a closed loop, completely cladding the carbon fiber bundles, and forming an outer cladding layer by the aluminum strip;
s4, extruding and micro-stretching the aluminum alloy outer cladding by adopting a multi-section cold rolling process, and removing gaps between carbon fibers and between the fibers and the aluminum alloy outer cladding to enable the carbon fibers to be completely oriented and parallel to the length direction, so as to obtain a completely compact coated cable; the reduction of the sectional area of each section of cold rolling is not more than 5 percent, so that the damage caused by overlarge primary deformation is prevented;
s5, removing partial stress and partial overstress of the cable through medium-frequency heating, solidifying and sintering metal and glass on the surface of the carbon fiber or solidifying and melting high polymer resin, and measuring residual stress according to hardness, wherein the hardness is increased by not more than 60% compared with that before extrusion;
s6, sealing gaps on the surface of the aluminum alloy outer cladding through welding to form an aluminum alloy outer cladding structure for completely sealing the carbon fiber composite core material; laser welding, ultrasonic welding, electric welding and the like can be adopted, so long as the gap is completely sealed, the welding atmosphere is argon, and the carbon fiber can bear high temperature higher than the melting point of metal under the argon atmosphere;
s7, continuously rolling at the temperature to deform the modified coating layer on the surface of the carbon fiber to form a compact coated cable, controlling the section size and the residual stress, and winding;
s8, placing the whole cable in an oven, heating to 230-320 ℃, keeping the temperature for 4-10 hours, curing or sintering the carbon fiber surface modified coating layer, and adjusting residual stress; the stress residual is monitored by a hardness measuring method, and the hardness is increased by 30-60%, more preferably 40-50% compared with the hardness of the aluminum alloy before extrusion.
The residual stress of the aluminum alloy outer cladding directly influences the strength of the cable, and the fatigue limit is increased, so that the stress change in the cable processing process is extremely important to continuously monitor, and the change of the residual stress can be obtained by measuring the change of hardness. The more common methods are a needle insertion method and an indentation method, and different test standards are formed, but the method is not suitable for the nondestructive test requirement of a continuous production line, so that the hardness change of cables at different production stages on the production line can be continuously measured and monitored by adopting ultrasonic waves.
Preferably, the heating temperature of step S5 is around the melting point, softening point, curing or sintering temperature of the modified cladding but below the melting point of the aluminum alloy cladding; when the modified coating layer is made of magnesium or aluminum, the heating temperature is higher than 450 ℃.
Preferably, in step S2, metal high temperature vapor deposition coating is adopted, and in a vacuum environment, the carbon fiber forms a layer of dense nano film on the surface of the carbon fiber in a metal vapor atmosphere, wherein the thickness of the film is 10-500 nm, more preferably 30-150 nm; the metal adopts magnesium, and the temperature of the metal bath is between 800 and 1100 ℃ to be lower than the boiling point of magnesium.
Preferably, all unreeling, reeling, metal vapor generators and coating areas are placed in the same vacuum cavity by adopting a roll-to-roll continuous process, and the vacuum pressure is lower than 10 -2 Pa, the roll-to-roll linear velocity is 0.2 to 5m/s, and the thickness of the metal film is controlled by adjusting the linear velocity and the temperature of the metal bath.
Preferably, a roll-to-roll continuous process and a water-soluble polyimide solution are adopted, carbon fibers are passed through the solution, the solution is uniformly coated on the surfaces of the carbon fibers under the assistance of ultrasonic waves, and then the carbon fibers are dried by a hot oven drying solvent; the thickness of the polymer material on the surface of the carbon fiber is controlled by adjusting the concentration of the polyimide solution, the concentration of the solution is 1-15%, more preferably 3-5%, and a polyimide film of 10-500 nm, more preferably 30-150 nm is formed on the surface of the carbon fiber; the temperature of the oven is 100-150 ℃, and the roll-to-roll linear speed is 0.1-5 m/s. The water-soluble polyimide is environment-friendly and has high operation safety coefficient, and the polyimide can be Cymer Iso Coat 401 in the United states.
According to the invention, a novel carbon fiber reinforced aluminum cable shell core structure is designed, high-strength and high-modulus carbon fibers are used as cores, aluminum alloy is used as a shell, and a modified coating layer is designed on the outer surface of the carbon fibers. Compared with a steel cable reinforced overhead cable, the lightweight cable is realized, the cable loss is lower, and the elastic modulus, the tensile strength and the flexibility of the cable are obviously improved, so that the durability and the practicability of the conductor cable are greatly improved.
Drawings
FIG. 1 is a schematic cross-sectional view of the present invention;
FIG. 2 is an enlarged view of a portion of FIG. 1;
FIG. 3 is a flow chart of the preparation process of the invention.
1 is an aluminum alloy outer cladding, 2 is a carbon fiber composite core material, 21 is a carbon fiber bundle, and 22 is a modified cladding.
Detailed Description
The invention is further described with reference to the accompanying drawings and specific examples:
example 1
The cable design is as follows: with an effective aluminium alloy cross-sectional area of 500mm 2 The carbon fiber composite aluminum stranded wire is used as an application direction, and the T300 with low cost is used as a raw material of the core material. Wherein the cross-sectional area of the carbon fiber composite core material 2 accounts for 6-7% of the cross-sectional area of the conductor, and is about 35mm 2 The diameter of the core material is 9mm, the content of the carbon fiber is 56%, 3K carbon fiber 420 bundles are needed, and the thickness of the aluminum alloy outer cladding 1 is 0.70mm. The aluminum alloy comprises 1.2% of manganese, 0.4% of magnesium, less than 0.4% of iron and other impurities, and the balance of aluminum; the surface of the carbon fiber bundle 21 is coated with a magnesium gas phase to form a modified coating layer 22.
From unreeling, depositing and reeling, all the equipment is placed in a vacuum box. 10 rolls of 3K T300 carbon fibers are simultaneously unreeled to form a 30K fiber bundle or 30K T300 is unreeled to form a fiber belt with the width of 100-200 mm through mechanical vibration, the fiber belt enters a metal magnesium deposition chamber, the temperature of a metal magnesium bath is 800-1100 ℃, the linear speed of the carbon fibers is 0.2-5 m/s, the thickness of a metal film can be controlled by adjusting the linear speed and the temperature of the metal bath, and then the fiber belt is collected on a reel. Vacuum pressure within the apparatusBelow 10 -2 Pa. The thickness of the nano thick metal film formed on the surface of the carbon fiber is 10-500 nm, such as 30nm, 100nm and 150nm.
Preparation of a composite cable: adopting a continuous process to produce the cable, firstly starting from unreeling the aluminum tape and the carbon fiber respectively, wherein the thickness dimension of the aluminum tape is 0.5mm, the width is 36.5mm, and the thickness is 1.3 times of the outer diameter perimeter of the cable by 9 mm; simultaneously, 42 bundles of 30K carbon fibers are placed, the linear speed is 1m/s, the hardness measurement in the related steps adopts an ultrasonic method, and in order to increase the internal stress of the aluminum alloy, the process comprises the following steps:
step S1: the aluminum strip for cladding is pressed into a U shape by a cold press, the outer diameter of the bottom of the U shape is 11.5mm, and the total height is about 15mm;
step S2: introducing the carbon fiber bundles subjected to cladding treatment into a U-shaped aluminum belt, and extruding the carbon fiber bundles towards the bottom by using a disc with the width slightly smaller than that of the U-shaped opening to realize compact filling;
step S3: the U-shaped aluminum strip is deformed into a circular tube in an extrusion mode to form a closed loop, and carbon fibers are completely coated to form an aluminum alloy outer cladding (shell);
step S4: extruding and micro-stretching the aluminum pipe by adopting a 15-stage cold rolling process, removing any gaps among carbon fibers and gaps among the carbon fibers and an aluminum alloy outer cladding, enabling the carbon fibers to be completely oriented and parallel to the length direction, and obtaining a completely compact coated cable and shell core structure, wherein the sectional area of each stage of cold rolling is reduced to 4.5 percent, and is not more than 5 percent, so that the damage caused by excessive primary deformation is prevented;
step S5: heating the cable to 450-550 ℃ through medium frequency, removing partial stress, integrating magnesium sintering on the surface of the carbon fiber, measuring residual stress according to hardness, and increasing the hardness by not more than 60% compared with the hardness before extrusion;
step S6: sealing gaps on the surface of the aluminum strip in an argon atmosphere in an electric welding mode, and completely sealing the aluminum pipe and the shell core structure;
step S7: continuously rolling at the temperature, deforming the modified coating layer on the surface of the fiber to form the most compact coated cable, controlling the section size and the residual stress, and rolling;
step S8: the whole cable is placed in an oven, the temperature is raised to 280-320 ℃, the heat preservation time is 4-10 hours, the residual stress is adjusted, the hardness is measured, the stress residual is monitored, and compared with the hardness before the extrusion of the aluminum alloy, the hardness is increased by 30-60%, and more preferably 40-50%. And obtaining the aluminum alloy coated carbon fiber composite cable with the diameter of 9 mm.
And (3) carrying out mechanical property test on the prepared composite cable, wherein the tensile strength is 1630MPa, the tensile modulus is 210GPa, and the porosity in the core material is 5-7%.
Example 2
The cable design is as follows: with an effective aluminium alloy cross-sectional area of 900mm 2 The carbon fiber composite aluminum stranded wire is used as an application direction, and the T300 with low cost is used as a raw material of the core material. Wherein the cross section area of the carbon fiber composite material core accounts for 6-7% of the cross section area of the conductor, and is about 54mm 2 The diameter of the core material is 11mm, the content of the carbon fiber is 57%, 3K T300 carbon fiber 640 bundles or 30K 64 bundles are needed, and the thickness of the aluminum alloy outer cladding is 0.80mm. The aluminum alloy comprises 1.2% of manganese, 0.4% of magnesium, less than 0.4% of iron and other impurities, and the balance of aluminum.
The surface of the carbon fiber is coated with polyimide: the fiber impregnation process of the polyimide aqueous solution can be linked with the subsequent cable compounding process. The continuous production line comprises unreeling, dipping, drying in an oven and reeling, or directly linked with the subsequent working procedure without reeling. Simultaneously unreeling 64 bundles of 30K T300 carbon fibers to form 1920K fiber bundles, feeding the fiber bundles into a polyimide solution tank, arranging an ultrasonic generator at the bottom of the tank, feeding the soaked carbon fibers into an oven with the power of 200-500W, drying at the temperature of 110-150 ℃, and collecting the carbon fiber bundles on a reel. The linear velocity of the carbon fiber is 0.2-5 m/s, and the thickness of the polyimide concentration control film is adjusted. Preferably, a water-soluble polyimide is used, for example, a polyimide is used in Cymer Iso Coat 401, preferably at a concentration of 3-5%, preferably deionized water, and the film thickness formed on the surface of the carbon fiber is between 10-500 nm, such as 30nm, 100nm, 150nm.
Preparation of a composite cable: adopting a continuous process to produce a cable, firstly starting from unreeling an aluminum belt and carbon fibers respectively, wherein the thickness dimension of the aluminum belt is 0.6mm, the width is 46.5mm, and the length is 1.35 times of the outer diameter perimeter of 11 mm; simultaneously, 64 bundles of 30K carbon fibers are placed, the linear speed is 0.7m/s, the hardness measurement in the related steps adopts an ultrasonic method, and in order to increase the internal stress of the aluminum alloy, the process comprises the following steps:
step S1: the aluminum strip for cladding is pressed into a U shape by a cold press, the outer diameter of the bottom of the U shape is 14.5mm, and the total height is about 20mm;
step S2: introducing the carbon fiber bundles subjected to cladding treatment into a U-shaped aluminum belt, and extruding the carbon fiber bundles towards the bottom by using a disc with the width slightly smaller than that of the U-shaped opening to realize compact filling;
step S3: the U-shaped aluminum strip is deformed into a circular tube in an extrusion mode to form a closed loop, and carbon fibers are completely coated to form an aluminum alloy shell;
step S4: extruding and micro-stretching the aluminum pipe by adopting a 20-stage cold rolling process, removing any fiber and pore space between the fiber and the aluminum pipe, and completely orienting the fiber in parallel with the length direction to obtain a completely compact coated cable and shell core structure, wherein the sectional area of each stage of cold rolling is reduced to 4.1 percent, not more than 5 percent, and the damage caused by overlarge primary deformation is prevented;
step S5: heating the cable to 300-350 ℃ through medium frequency, removing partial stress, performing primary solidification on polyimide on the surface of the molten carbon fiber, and measuring residual stress according to hardness, wherein the hardness is increased by not more than 60% compared with the hardness before extrusion;
step S6: sealing gaps on the surface of the aluminum strip in an argon atmosphere in an electric welding mode, and completely sealing the aluminum pipe and the shell core structure;
step S7: continuously rolling at the temperature, deforming the modified coating layer on the surface of the fiber to form the most compact coated cable, controlling the section size and the residual stress, and rolling;
step S8: the whole cable is placed in an oven, the temperature is raised to between 250 and 300 ℃, the heat preservation time is 4 to 10 hours, the residual stress is adjusted, the hardness is measured, the stress residual is monitored, and compared with the hardness before the extrusion of the aluminum alloy, the hardness is increased by 30 to 60 percent, and more preferably 40 to 50 percent. And obtaining the aluminum alloy coated carbon fiber composite cable with the diameter of 11 mm.
And (3) carrying out mechanical property test on the prepared composite cable, wherein the tensile strength is 1550MPa, the tensile modulus is 208GPa, and the porosity in the core material is 5-7%.
Table 1 the relationship between the percentage of cross-sectional area of different carbon fibers (S) to total area, the number of bundles of 3K carbon fibers required (x) and the variation of the thickness of the housing (t) when the wire diameter is varied from 3 to 15 mm. The theoretical maximum occupation percentage of the carbon fiber is pi/4, about 78.5%, the carbon fiber can actually occupy less than 70% of the total section due to the needed shell, when the thickness of the shell is 0.3-5 mm, the main part is from the table, the thinner wire diameter can adopt less carbon fiber content, and the higher carbon fiber content needs larger wire diameter. From the practical application of overhead stranded wires, the sectional area of the conductor exceeds 500mm 2 The above is mainly that some cables with ultra-large capacity reach 1500mm 2 . The diameter of the reinforcing core is more than 8mm, and the percentage of carbon fibers is preferably more than 60%.
Table 1a: different wire diameters and carbon fiber percentages (S), required 3K strands (x) and shell thickness (t).
Table 1 b): different wire diameters and carbon fiber percentages (S), required 3K strands (x) and shell thickness (t).
The foregoing detailed description of the invention has been presented for purposes of illustration and description, but is not intended to limit the scope of the invention, i.e., the invention is not limited to the details shown and described.
Claims (11)
1. The preparation process of the carbon fiber composite aluminum alloy overhead cable is characterized by comprising the following steps of: adopting a continuous production line with the linear speed of 0.1-5 m/s, respectively unreeling the aluminum belt and the carbon fiber, carrying out the following steps,
s1, pressing an aluminum belt for forming an aluminum alloy outer cladding into a U-shaped structure through a cold press, and extruding a disc with the width slightly smaller than that of an opening of the U-shaped structure towards the bottom to realize compact filling;
s2, introducing the carbon fiber bundles which are subjected to coating treatment and provided with the modified coating layer into a U-shaped aluminum belt;
s3, deforming the U-shaped aluminum strip into a circular tube shape or a hexagonal tube shape in an extrusion mode to form a closed loop, completely cladding the carbon fiber bundles, and forming an outer cladding layer by the aluminum strip;
s4, extruding and micro-stretching the aluminum alloy outer cladding by adopting a multi-section cold rolling process, and removing gaps between carbon fibers and between the fibers and the aluminum alloy outer cladding to enable the carbon fibers to be completely oriented and parallel to the length direction, so as to obtain a completely compact coated cable; the reduction of the sectional area of each section of cold rolling is not more than 5 percent, so that the damage caused by overlarge primary deformation is prevented;
s5, removing partial stress and partial overstress of the cable through medium-frequency heating, solidifying and sintering metal and glass on the surface of the carbon fiber or solidifying and melting high polymer resin, and measuring residual stress according to hardness, wherein the hardness is increased by not more than 60% compared with that before extrusion;
s6, sealing gaps on the surface of the aluminum alloy outer cladding through welding to form an aluminum alloy outer cladding structure for completely sealing the carbon fiber composite core material;
s7, continuously rolling at the temperature to deform the modified coating layer on the surface of the carbon fiber to form a compact coated cable, controlling the section size and the residual stress, and winding;
s8, placing the whole cable in an oven, heating to 230-320 ℃, keeping the temperature for 4-10 hours, curing or sintering the carbon fiber surface modified coating layer, and adjusting residual stress; the hardness is measured to monitor stress residual, and compared with the hardness of the aluminum alloy before extrusion, the hardness is increased by 30-60%.
2. The process for preparing a carbon fiber composite aluminum alloy overhead cable according to claim 1, wherein: the heating temperature of step S5 is near the melting point, softening point, solidification or sintering temperature of the modified cladding but below the melting point of the aluminum alloy overclad; when the modified coating layer is made of magnesium or aluminum, the heating temperature is higher than 450 ℃.
3. The process for preparing a carbon fiber composite aluminum alloy overhead cable according to claim 1, wherein: in the step S2, metal high-temperature vapor deposition coating is adopted, and a layer of compact nano film is formed on the surface of the carbon fiber through a metal vapor atmosphere in a vacuum environment, wherein the thickness of the film is 10-500 nm; the metal adopts magnesium, and the temperature of the metal bath is between 800 and 1100 ℃ to be lower than the boiling point of magnesium.
4. The process for preparing a carbon fiber composite aluminum alloy overhead cable according to claim 1, wherein: all unreeling, reeling, metal vapor generators or film coating areas are placed in the same vacuum cavity by adopting a reel-to-reel continuous process, and the vacuum pressure is lower than 10 -2 Pa, the roll-to-roll linear velocity is 0.2 to 5m/s, and the thickness of the metal film is controlled by adjusting the linear velocity and the temperature of the metal bath.
5. The process for preparing a carbon fiber composite aluminum alloy overhead cable according to claim 1, wherein: the method comprises the steps of adopting a roll-to-roll continuous process and a water-soluble polyimide solution, enabling carbon fibers to pass through the solution, uniformly coating the solution on the surfaces of the carbon fibers under the assistance of ultrasonic waves, and drying the carbon fibers by a hot oven drying solvent;
the thickness of the polymer material on the surface of the carbon fiber is controlled by adjusting the concentration of the polyimide solution, the concentration of the solution is 1-15%, a polyimide film with the thickness of 10-500 nm is formed on the surface of the carbon fiber, the temperature of an oven is 100-150 ℃, and the roll-to-roll linear speed is 0.1-5 m/s.
6. The process for preparing a carbon fiber composite aluminum alloy overhead cable according to claim 1, wherein: the prepared carbon fiber composite aluminum alloy overhead cable comprises an aluminum alloy outer cladding and a core material, wherein the aluminum alloy outer cladding is coated outside the core material to form a shell core structure; the core material consists of a plurality of carbon fiber composite core materials coated with modified coating layers on the surfaces, each carbon fiber composite core material takes a plurality of carbon fiber bundles as a main body, and the coating layers are coated outside the carbon fibers; the carbon fiber bundles account for 10-80% of the cross section area of the carbon fiber composite core material, and the porosity of the carbon fiber composite core material is 3-15%; the tensile strength of the whole cable exceeds 300MPa, and the tensile modulus exceeds 200GPa.
7. The process for preparing a carbon fiber composite aluminum alloy overhead cable according to claim 6, wherein: the aluminum component of the aluminum alloy outer cladding is not less than 98 percent, and manganese and magnesium are added to form the aluminum alloy.
8. The process for preparing a carbon fiber composite aluminum alloy overhead cable according to claim 7, wherein: the raw material form for manufacturing the aluminum alloy outer cladding is a strip with the thickness of 0.2-4.5 mm, and the width of the strip is 1.3-2 times of the circumference of a cable to be produced, so that the aluminum alloy strip can completely cover the carbon fiber composite core material.
9. The process for preparing a carbon fiber composite aluminum alloy overhead cable according to claim 6, wherein: the modified coating layer is made of metal, ceramic, glass or heat-resistant high polymer material, and the thickness of the modified coating layer is 10-500 nm; the modified coating layer is used as a bonding material of the carbon fiber and is used for realizing local bonding of the carbon fiber, so that the porosity in the carbon fiber composite core material is 5-10%, the flexibility of the cable is increased, the tensile strength of the whole cable exceeds 1500MPa, and the tensile modulus exceeds 250GPa.
10. The process for preparing a carbon fiber composite aluminum alloy overhead cable according to claim 9, wherein: the modified coating layer is made of magnesium, aluminum or copper, and the thickness is 30-150 nm.
11. The process for preparing a carbon fiber composite aluminum alloy overhead cable according to claim 6, wherein: the carbon fiber bundles are bundle-shaped carbon fibers with tensile strength of more than 3000MPa and tensile modulus of more than 220GPa, and are 3K, 6K, 9K, 12K or 24K, and the bundles are formed by adopting multi-bundle ply-bonding.
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| CN1918671A (en) * | 2004-02-13 | 2007-02-21 | 3M创新有限公司 | Metal-cladded metal matrix composite wire |
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